Molded panel having a decorative facing and made from a blend of natural and plastic fibers

Abstract

A laminated panel (60) made of a reinforced non-woven flexible mat (10) with a content of thermoplastic fibers which is provided on at least one side with a plastic-containing decorative layer (72) The mat (10) is connected with the decorative layer (72) by the use of pressure and heat via an intermediate scrim layer (74) having thermoplastic fibers. The process for forming a panel (60) includes preheating the mat (10) by passing a heated gaseous flow through the mat to evenly heat the mat throughout. A layer of unheated decorative vinyl (71) and the preattached scrim layer (74) are placed in a mold (30). The preheated mat (10) is then placed into the mold (30). The mold is promptly closed and pressed to bond the layers of mat, scrim, and decorative vinyl layer together to form the laminated panel.

Dependencies are inferred from the claim text.