Abstract: An improved process, particularly adapted for making that type of sheet vinyl covering materials known as inlaids by first depositing resinous particles on a wet ungelled layer of PVC plastisol or organosol and then passing the sheet between a heated, cylindrical surface and a means for gradually and uniformly increasing the contact pressure between the cylindrical surface and the coated surface of the sheet. Upon completion of the step, a substantially uniformly, gelled matrix layer is produced, with the resinous particles embedded therein, and having a smooth and firm surface of uniform thickness.

Abstract: A relatively inexpensive mat is provided which through the application of heat and pressure readily can be densified to form rigid shaped articles having a reduced overall density. The mat is substantially free of a binder (e.g., a latex binder) and consists essentially of a substantially radom array of (a) relatively coarse cellulosic fibers, (b) thermoplastic synthetic polymer fibrils, (c) non-fibrous thermoplastic synthetic polymer particles, (d) substantially void-free substantially water-insoluble particulate inorganic material (e.g., talc), and (e) particulate void-containing substantially water-insoluble inorganic material (e.g., expanded volcanic glass) having a lesser density than component (d) in the specified quantities. A plurality of the mats while stacked together with similar mats of greater density on at least the upper and lower surfaces may be subjected to heat and pressure to accomplish densification and thermal bonding within and between adjoining mats to form a laminate.

Abstract: A relatively inexpensive mat is provided which through the application of heat and pressure readily can be densified to form rigid shaped articles. The mat is substantially free of a binder (e.g., a latex binder) and consists essentially of a substantially random array of (a) relatively coarse cellulosic fibers, (b) thermoplastic synthetic polymer fibrils, (c) non-fibrous thermoplastic synthetic polymer particles, and (d) substantially void-free substantially water-insoluble particulate inorganic material (e.g., talc) in the specified quantities. The mat preferably is formed by wet-laying from an aqueous dispersion wherein the (c) and (d) components are dispersed among and physically retained by the (a) and (b) components. A plurality of the mats while stacked may be subjected to heat and pressure to accomplish densification and thermal bonding within and between adjoining sheets to form a laminate.