Leucadia, Inc.

William Reeve

Robert DePetris

A method for making a reinforced fibrous mat having a net layer between two fibrous layers and the reinforced fibrous mat made therefrom is disclosed. The net layer improves handleability of the fibrous mat. The fibrous mat may be used as is or it may be molded to form a molded product. A thermoplastic binder such as latex or starch is used in forming the fibrous layers. A thermoset binding agent such as a phenolic resin is added to the fibers if the reinforced fibrous mat is molded.

Process for making a reinforced fibrous mat and product made therefrom

A molded product is made having uniform strength throughout the product. The molded product is made by mixing together fibrous materials such as cellulosic fibers and a heat-fusible binding agent such as a phenolic resin to form an admixture. The admixture is then sprayed with a binding agent such as starch as it is dispersed to form a fibrous molding preform. Heat and pressure are applied to the molding preform to form a molded product.

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Burlington, NJ, United States of America

William Reeve