Molded fibrous panel with finished surface

Details Molded fibrous panel with finished surface Molded fibrous panel with finished surface

E - Fixed Constructions

04

F

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E04F 13/16 (2006.01) B28B 1/52 (2006.01) B28B 5/02 (2006.01) B28B 11/08 (2006.01) B29C 67/24 (2006.01) B29C 70/08 (2006.01) B29C 70/46 (2006.01) B32B 17/04 (2006.01) B29C 43/48 (2006.01) B29C 51/08 (2006.01)

Patent

CA 1036778

A B S T R A C T A coated, decorative panel or tile of molded fibrous material and a method of making the same. A pad of preferably glass fibers held together by a binder in an uncured state, is compressed and heated in a matched metal contoured mold to the desired permanent shape, after which a finishing coat is applied. The resulting panel has an obverse face with a high fidelity reproduction of the mold surface. The panel fibers are heterogeneously arranged, being mostly parallel to the panel's contoured surface, with some lying angularly thereto. The surface appearance is improved by positioning a non-woven fibrous sheet on the uncured pad before molding. The non-woven sheet and the pad are placed between two mold halves, one of which is contoured to form a front face of the panel, with the non-woven sheet side of the pad being adjacent the contoured mold half. The mold halves move together, com- pressing the fibrous material, while heat is applied to bend the fibrous layer. The mold halves are then separated, and the contoured panel removed. The non- woven sheet now conforms to the contoured surface of the mold along with the fibrous pad, and also bridges more open portions of the panel's surface while masking non-uniform areas thereof.

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