Textiles are re-cycled by grinding and scatter-laying onto a needle-punched web optionally containing low-melting material, followed by laying a second needle-punched web over the scattered layer and re-needling the three layers before applying heat or heat and pressure to activate the low-melting ground material present within the layers. Additional low-melt ground material is optionally blended into the ground textile if low melt components are absent or insufficient to bond the composite. The ground material is driven and dispersed into the surrounding web layers with at least part of the material being adjacent the two outer surfaces. The physical properties of the composite can be adjusted by selecting suitable combinations including but not limited to needling stroke depth, needling density, needle gage, low-melt content, heat finishing conditions, and relative layer weights. The final composites can optionally be reintroduced into the original end use and include significant percentages of recycled material.

Textiles are re-cycled by grinding and scatter-laying onto a needle-punched web optionally containing low-melting material, followed by laying a second needle-punched web over the scattered layer and re-needling the three layers before applying heat or heat and pressure to activate the low-melting ground material present within the layers. Additional low-melt ground material is optionally blended into the ground textile if low melt components are absent or insufficient to bond the composite. The ground material is driven and dispersed into the surrounding web layers with at least part of the material being adjacent the two outer surfaces. The physical properties of the composite can be adjusted by selecting suitable combinations including but not limited to needling stroke depth, needling density, needle gage, low-melt content, heat finishing conditions, and relative layer weights. The final composites can optionally be reintroduced into the original end use and include significant percentages of recycled material.

A method for producing a veneered board having a veneer and a carrier board having improved use properties includes the steps of providing a veneer and a carrier board, providing a sheet of paper impregnated with binder, the sheet of paper being arranged in a stack of materials to be pressed between an upper face of the carrier board and a lower face of the veneer, and pressing the stack of materials to be pressed. The sheet of paper is impregnated with a binder, the sheet of paper impregnated with binder is pre-dried so that it is still sticky, at least one additive is applied onto the pre-dried, still sticky binder, and the sheet of paper which is impregnated with binder and provided with an additive is dried to a residual moisture content of up to 8%.

A building panel, such as a floor panel, having a core comprising at least one or more of a thermoplastic material, a thermoset material, a mineral based material or a combination thereof. The building panel further including a first arrangement, arranged on said core, having a surface layer and a sublayer, where the sublayer is arranged between the core and the surface layer.

A building panel, such as a floor panel, having a core comprising at least one or more of a thermoplastic material, a thermoset material, a mineral based material or a combination thereof. The building panel further including a first arrangement, arranged on said core, having a surface layer and a sublayer, where the sublayer is arranged between the core and the surface layer.

A process for making a card includes the steps of forming a core layer having a first surface and a second surface, disposing an uncured decorative ceramic layer of ceramic particles disposed in a resin binder over the first surface of the core layer, such as by spray coating, and curing the uncured decorative ceramic layer to form a cured decorative ceramic layer. Card products of the process may have a core layer of metal, ceramic, or a combination thereof that form a bulk of the card.

A process for making a card includes the steps of forming a core layer having a first surface and a second surface, disposing an uncured decorative ceramic layer of ceramic particles disposed in a resin binder over the first surface of the core layer, such as by spray coating, and curing the uncured decorative ceramic layer to form a cured decorative ceramic layer. Card products of the process may have a core layer of metal, ceramic, or a combination thereof that form a bulk of the card.

In-line systems and in-line methods are described that can be used to provide lightweight reinforced thermoplastic composite articles that include a textured or an embossed film layer. The textured or embossed film layer can provide one or more of water resistance, flame retardancy, a desired surface roughness, enhanced peel strength, enhanced acoustic absorption or other desired properties. The lightweight reinforced thermoplastic composite articles that include a textured or an embossed film layer can be used in building applications, in recreational vehicle applications and in other applications as desired.

In-line systems and in-line methods are described that can be used to provide lightweight reinforced thermoplastic composite articles that include a textured or an embossed film layer. The textured or embossed film layer can provide one or more of water resistance, flame retardancy, a desired surface roughness, enhanced peel strength, enhanced acoustic absorption or other desired properties. The lightweight reinforced thermoplastic composite articles that include a textured or an embossed film layer can be used in building applications, in recreational vehicle applications and in other applications as desired.

A tile-type decorative flooring material includes a surface-processed layer, a clear layer, a design-print layer, an underlayer, and a micro-embossed plastic foam part having a plastic foam layer and an adhesive film layer with micro-embossing. The flooring material provides a significant improvement in terms of slippage between the product and the floor surface in a construction process not using an adhesive.