Moldable fibrous mat and product molded therefrom
AssigneeVan Dresser Corporation
InventorsRichard P. Doerer, Joseph T. Karpik
Life of this patent
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Abstract
A moldable fibrous mat from which a permanently rigid product of predetermined shape can be molded by the application of heat and/or pressure. The mat consists essentially of base fibers and carrier fibers and a thermosetting ingredient, with the base fibers having a substantially higher softening temperature, if any, than the carrier fibers. The fibers intertwine to resist separation. The carrier fibers are bonded to the base fibers and to each other to form connections, the thermoset remaining dormant in the making of the mat. There is also disclosed a method by which the moldable fibrous mat is made and product made from the mat, which product may be of uniform density or have areas of differing density.
Claims13
A soft, flexible, handleable fibrous mat from which a permanently shaped product can be molded by the application of predetermined heat and pressure in a compression molding operation, said mat consisting essentially of cellulose base fibers, and means for linking and bonding and for resisting separation of said base fibers and adding tensile strength to said mat including carrier fibers intertwined with said based fibers and bonded to said base fibers and to each other forming connections therebetween, said mat having, in addition to said base fibers and means for linking and bonding, a dormant, uncured thermosetting ingredient, said thermosetting ingredient having a curing temperature not greater than the temperature of said compression molding operation so that said thermosetting ingredient will cure when said mat is subjected to said heat and pressure in said compression molding operation.
A soft, flexible, handleable fibrous mat from which a permanently rigid, shaped product can be molded by the application of heat and pressure in a compression molding operation, said mat being made of a mixture with percentages by weight consisting of 85% wood fibers, 5% blended non-thermoplastic textile fibers of 35% cotton and 65% polyester, 5% low melt point thermoplastic polyester resin which softens and becomes tacky at about 225.degree. F., and 5% phenolic resin which cures at about 325.degree. F. or higher, said thermoplastic resin bonding said fibers to each other forming connections therebetween, said phenolic resin being uncured but adapted to cure when said mat is subjected to heat and pressure in said compression molding operation, said bonding of said fibers to each other by said thermoplastic resin being caused by heating said thermoplastic resin to its tack point but below the curing temperature of said phenolic resin to avoid any curing of said phenolic resin.
Dependencies are inferred from the claim text.