Disclosed herein is a method of manufacturing an improved cover board product with a panel. In some embodiments, the method includes preparing fragments into an assembly; mixing the fragments and an adhesive into a blended core furnish; applying the adhesive to a top side of a bottom layer fabric in the assembly; forming a core mat of the blended core furnish on top of the adhesive; applying the adhesive to a top side of the core mat; applying a surface layer fabric on the top side of the adhesive; pressing the assembly; and cutting and trimming the assembly to form panels.

A method of manufacturing a building panel with a decorative surface layer, a core and a balancing and/or protective layer, wherein the method includes applying a first layer of a first powder based mix, including wood fibres and a thermosetting binder, on a core; applying a liquid substance on the first powder based mix; drying the first powder based mix; turning the core with the dried first powder based mix such that the first powder based mix points downwards; applying a second layer on the upper part of the core; and curing the first and second layers by providing heat and pressure, wherein the first layer forms the balancing and/or protective layer and the second layer forms the decorative surface layer in the building panel.

An improved cover board product with a panel comprised of three discrete layers: a top surface layer comprised of either paper or a fiberglass web, a bottom surface layer comprised of either paper or a fiberglass web, and a core layer comprised of discrete paper fragments and polypropylene fragments, which are connected by use of a thermoplastic bonding resin, including polyethylene. The bonding resin is generally attached in a random pattern to less than 100% of the paper fragment and polypropylene fragment surface area. The paper fragments are generally shaped as irregular plates. The polypropylene fragments can have multiple shape types. The two different fragment types are randomly distributed in the core layer relative to each other. The core layer includes small voids in and around the particles, which improves flexibility. The core layer is attached to the top and bottom surface layers by use of a thermoplastic adhesive, including polyethylene.

A method for manufacturing a plastic composite uses recycled thermoplastic material comprising the steps of (1) providing flakes of thermoplastic materials to be recycled; (2) mixing the thermoplastic flakes, thereby forming a thermoplastic matrix having a first melting temperature; (3) forming or providing a web-structure of a predetermined thickness from fibers having a second melting temperature higher than the first melting temperature; (4) evenly distributing the thermoplastic matrix of thermoplastic flakes over the web-structure; (5) optionally forming or providing a second web-structure and placing it over the thermoplastic matrix; (6) optionally repeating steps (4) and (5); and (7) heating the web at a temperature between the first and second temperature using a thermoforming process.

A main flooring part for a vehicle comprising an aesthetic surface layer and a spacer layer, whereby both layers are consolidated and laminated to the adjacent layer to form the flooring part, characterised in that both layers comprise pulled fibers from textile waste and a binder, and whereby the aesthetic surface layer is thermally compressed to form a stiff layer and whereby the fibers of the surface of the aesthetic surface layer are heat set to smooth the aesthetic surface.

The article includes a first layer having a backing and upstanding posts or fibrous loop protruding from the backing and a second layer of at least one of dried or cured composite including at least one of gypsum, lime, or cement. The fibrous loop includes at least one of arcuate portions projecting from the first surface of the backing web, a knitted fibrous web, or a needle-punched nonwoven web. The upstanding posts may have at least one of the following features: a density of up to 248 per square centimeter, a proximal end attached to the backing and a distal end larger in area than a cross-sectional area of the proximal end with the distal end having overhanging portions extending in at least two opposing directions, or a proximal end attached to the backing and a distal end with no overhanging portion. Methods of making the article are also described.

An improved cover board product with a panel comprised of three discrete layers: a top surface layer comprised of either paper or a fiberglass web, a bottom surface layer comprised of either paper or a fiberglass web, and a core layer comprised of discrete paper fragments and polypropylene fragments, which are connected by use of a thermoplastic bonding resin, including polyethylene. The bonding resin is generally attached in a random pattern to less than 100% of the paper fragment and polypropylene fragment surface area. The paper fragments are generally shaped as irregular plates. The polypropylene fragments can have multiple shape types. The two different fragment types are randomly distributed in the core layer relative to each other. The core layer includes small voids in and around the particles, which improves flexibility. The core layer is attached to the top and bottom surface layers by use of a thermoplastic adhesive, including polyethylene.

The invention relates to a method of producing a sound proofing trim panel comprising the steps of providing an elastically compressible lower layer, heating the lower layer and placing it in a mould to shape it to form a spring layer of a spring-mass type damping system. The method further includes associating the lower layer with an upper layer, to form the mass of the spring-mass system. According to the invention, the lower layer comprises a blend of elastically compressible foam flakes forming at least 80 wt.-% of the lower layer and being mixed with binder fibres. The fibres comprising a core and a sheath that is fusible at a moderate temperature, and the flakes being bonded to one another by means of the fusing of the sheath forming a binder, such that the lower layer takes the form of a bonded foam.

A method for laminating profile and plate materials produced from processed mixed plastic waste and other plastic surfaces comprises steps of collecting and processing of mixed plastic waste for recycling for making profile and plate materials and lamination of profile and plate materials produced from processed mixed plastic waste, wherein the lamination of profile and plate materials produced from processed mixed plastic waste comprises stabilizing the profile temperature before lamination; determining the surface quality; making the surface quality of profile suitable by propane gas treatment of the profile; heating the profile surface before the lamination process; heating the adhesive right before the lamination; applying the adhesive to the laminate surface; carrying out the lamination process; and directing the laminated profiles for storying.

A method for manufacturing a breathable hybrid leather includes: a raw material supply step of supplying the natural leather of recycled leather; a step of applying a hot-melt adhesive to the upper surface of the leather raw material; a bonding step of supplying a fabric to the upper surface of the adhesive layer and applying heat and pressure to the leather raw material, the adhesive layer, and the fabric to obtain a bonded fabric; and a step of ironing and coating the bonded fabric a plurality of times.