Relatively inexpensive thermoformable mat and rigid laminate for

Details Relatively inexpensive thermoformable mat and rigid laminate for Relatively inexpensive thermoformable mat and rigid laminate for

1986-12-22

1988-09-06

Chin, Peter

Paper making and fiber liberation

Processes and products

Multi-layer waterlaid webs or sheets

162146, 1621641, 1621681, 162169, 1621811, 162183, 162206, 162223, 162224, D21H 102

Patent

active

047691093

ABSTRACT:
A relatively inexpensive mat is provided which through the application of heat and pressure readily can be densified to form rigid shaped articles. The mat is substantially free of a binder (e.g., a latex binder) and consists essentially of a substantially random array of (a) relatively coarse cellulosic fibers, (b) thermoplastic synthetic polymer fibrils, (c) non-fibrous thermoplastic synthetic polymer particles, and (d) substantially void-free substantially water-insoluble particulate inorganic material (e.g., talc) in the specified quantities. The mat preferably is formed by wet-laying from an aqueous dispersion wherein the (c) and (d) components are dispersed among and physically retained by the (a) and (b) components. A plurality of the mats while stacked may be subjected to heat and pressure to accomplish densification and thermal bonding within and between adjoining sheets to form a laminate. The resulting cellulosic fiber reinforced product can be used to advantage as a shaped rigid panel for use as an inner automobile door liner or in similar end uses which require a rigid sheet or panel having a predetermined configuration. A decorative surface optionally may be applied to the resulting article.

REFERENCES:
patent: 3325345 (1967-06-01), Hider
patent: 4225383 (1980-09-01), McReynolds
patent: 4379808 (1983-04-01), Cole et al.
patent: 4451539 (1984-05-01), Vallee et al.
patent: 4481075 (1985-11-01), Dailly et al.

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