Method for preparing reinforced thermoset articles

Claim 1

A process for preparing reinforced thermoset article comprising (a) preparing a heat-fusible reinforced polymer sheet by forming a dilute aqueous slurry of (i) from about 19 to about 79 percent of solid heat-fusible organic polymer particles, (ii) from about 10 to about 80 percent of reinforcing fibers, and (iii) from about 1 to about 10 percent of a latex binder of a substantially water-insoluble organic polymer having either anionic or cationic bound charges, the percentages being by weight based on a dry solids basis; (b) flocculating the slurry during agitation with a polymeric flocculant opposite in charge to that of the latex binder; (c) collecting the solids in the form of a mat; (d) dewatering the mat; (e) drying the mat; (f) densifying and consolidating the mat with heat and pressure to a densified composite; (g) permitting the densified composite to loft to a predetermined shape; (h) impregnating said formed lofted composite with a thermoset resin composition; and (i) curing said thermoset resin composition.