Moldable fibrous mat and method of making the same

Claim 1

A two-stage method of manufacturing a permanently rigid shaped end product comprising: (1) in a first stage and by a dry process, making a soft, flexible, handleable fibrous mat by providing a mixture consisting essentially of cellulose base fibers, linking and activatable bonding means including carrier fibers, and a thermosetting ingredient, forming said mixture into a mat in which said fibers are interspersed, activating said bonding means to cause said carrier fibers to bond to said base fibers and to each other forming connections therebetween and holding said fibers together, said thermosetting ingredient remaining in an uncured state during said activation of said bonding means and (2) thereafter making said end product in a second stage at any later time by subjecting said mat to sufficient heat and pressure in a compression molding operation to cause said thermosetting ingredient to cure and to compress the material to the desired thickness and density, and molding and bonding an attachment to said end product simultaneously with the making of said end product and in said compression molding operation, thereby completing the manufacture of said end product.