Method of forming a shaped product

Claim 1

A METHOD OF FORMING A RESIN IMPREGNATED AND SHEET COVERED AND SHAPED PRODUCT HAVING RELATIVELY SHARP IRREGULARITIES IN ITS SURFACE, COMPRISING: (A) WETTING AND HEATING A RESIN CONTAINING FIBERBOARD TO PRODUCE AN ATMOSPHERE OF MOISTURE LADENED STEAM AROUND SAID FIBERBOARD TO IMPREGNATE SAID FIBERBOARD WITH WATER TO SOFTEN THE FIBERS IN SAID BOARD, SAID FIBERBOARD HAVING: (1) A PERMEABLE RESINOUS COATING DIRECTLY APPLIED TO AT LEAST ONE SIDE OF SAID FIBERBOARD, SAID COATING HAVING: (A) A THICKNESS OF BETWEEN ABOUT 1 AND 5 MILS. (B) AN ELASTOMERIC NATURE TO PERMIT STRETCHING AROUND THE SHARP IRREGULARITIES IN THE SURFACE OF THE RESULTING PRODUCT AND TO PREVENT RUPTURE OF SAID FIBERBOARD, (C) A LOW RESISTANCE TO THE TRANSMISSION OF MOISTURE VAPOR FOR RELEASE OF THE WATER IN THE FIBERBOARD DURING THE FORMING AND SHAPING OF THE FINAL PRODUCT, (D) ADHESIVE PROPERTIES WHEN SUBJECTED TO HEAT AND PRESSURE FOR PRODUCING AN INTEGRAL FINAL PRODUCT, AND (E) COMPRISING A POLYMER OF AT LEAST 50% BY WEIGHT OF AT LEAST ONE RESIN SLECTED FROM THE GROUP CONSISTING OF: POLYVINYL ACETATE, POLYSTYRENE, POLYBUTADIENE, BUTADIENE ACRYLONITRILE RUBBER LATEX, POLYISOBUTYLENE RUBBER LATEX, AND NATURAL RUBBER LATEX; AND HAVING: (2) A PERMEABLE STRETCHABLE COVERING SHEET ADJACENT SAID COATING FOR FORMING AROUND THE IRREGULARITIES IN THE SURFACE OF THE FINAL PRODUCT WITH RUPTURING, AND (B) THEREAFTER APPLYING BOTH HEAT OF ABOUT 180*F. AND A PRESSURE OF ABOUT 1,000 POUNDS PER SQUARE INCH SIMULTANEOUSLY TO SAID WATER IMPREGNATED AND COATED FIBERBOARD AND SAID STRETCHABLE SHEET IN A HEATED SHAPED MOLD IN A PRESS FOR BETWEEN ABOUT 30 AND 60 SECONDS TO PRODUCE AN INTEGRAL SHAPED MOLDED PRODUCT THEREFROM, WHEREBY SAID COATING UNDER SAID HEAT AND PRESSURE OF THIS STEP ADHERES SAID STRETCHABLE COVERING SHEET TO SAID SHAPED FIBERBOARD AND PREVENTS RUPTURE OF SAID FIBERBOARD, AND WHEREBY THE MOISTURE VAPOR PERMEABILITY OF SAID COATING PERMITS THE WATER WHICH HAS BEEN IMPREGNATED INTO THE FIBERBOARD TO ESCAPE FROM THE FIBERBOARD WITHOUT BLISTERING SAID COATING.

Claim 2

A METHOD OF FORMING A RESIN IMPREGNATED AND SHEET COVERED AND SHAPED PRODUCT HAVING RELATIVELY SHARP IRREGULARITIES IN ITS SURFACE, COMPRISING: (A) WETTING AND HEATING A RESIN CONTAINING FIBERBOARD TO PRODUCE AN ATMOSPHERE OF MOISTURE LADENED STEAM AROUND SAID FIBERBOARD TO IMPREGNATE SAID FIBERBOARD WITH WATER TO SOFTEN THE FIBERS IN SAID BOARD, SAID FIBERBOARD HAVING: (1) A PERMEABLE RESINOUS COATING DIRECTLY APPLIED TO AT LEAST ONE SIDE OF SAID FIBERBOARD, SAID COATING HAVING: (A) A THICKNESS OF BETWEEN ABOUT 1 AND 5 MILS. (B) AN ELASTOMERIC NATURE TO PERMIT STRETCHING AROUND THE SHARP IRREGULARITIES IN THE SURFACE OF THE RESULTING PRODUCT AND TO PREVENT RUPTURE OF SAID FIBERBOARD, (C) A LOW RESISTANCE TO THE TRANSMISSION OF MOISTURE VAPOR FOR RELEASE OF THE WATER IN THE FIBERBOARD DURING THE FORMING AND SHAPING OF THE FINAL PRODUCT, (D) ADHESIVE PROPERTIES WHEN SUBJECTED TO HEAT AND PRESSURE FOR PRODUCING AN INTEGRAL FINAL PRODUCT, AND (E) COMPRISING A POLYMER OF AT LEAST 50% BY WEIGHT OF AT LEAST ONE RESIN SLECTED FROM THE GROUP CONSISTING OF: POLYVINYL ACETATE, POLYSTYRENE, POLYBUTADIENE, BUTADIENE ACRYLONITRILE RUBBER LATEX, POLYISOBUTYLENE RUBBER LATEX, AND NATURAL RUBBER LATEX; AND HAVING: (2) A PERMEABLE STRETCHABLE COVERING SHEET ADJACENT SAID COATING FOR FORMING AROUND THE IRREGULARITIES IN THE SURFACE OF THE FINAL PRODUCT WITH RUPTURING, AND (B) THEREAFTER APPLYING BOTH HEAT OF ABOUT 180*F. AND A PRESSURE OF ABOUT 1,000 POUNDS PER SQUARE INCH SIMULTANEOUSLY TO SAID WATER IMPREGNATED AND COATED FIBERBOARD AND SAID STRETCHABLE SHEET IN A HEATED SHAPED MOLD IN A PRESS FOR BETWEEN ABOUT 30 AND 60 SECONDS TO PRODUCE AN INTEGRAL SHAPED MOLDED PRODUCT THEREFROM, WHEREBY SAID COATING UNDER SAID HEAT AND PRESSURE OF THIS STEP ADHERES SAID STRETCHABLE COVERING SHEET TO SAID SHAPED FIBERBOARD AND PREVENTS RUPTURE OF SAID FIBERBOARD, AND WHEREBY THE MOISTURE VAPOR PERMEABILITY OF SAID COATING PERMITS THE WATER WHICH HAS BEEN IMPREGNATED INTO THE FIBERBOARD TO ESCAPE FROM THE FIBERBOARD WITHOUT BLISTERING SAID COATING.