Abstract: A process for producing a low density fibrous mat from which a molded article may be formed by molding at elevated temperature, and which comprises a first layer of fibers, as well as thermosetting and thermoplastic binders, and at least one open covering layer of tangled fibers connected thereto is disclosed. The process including the steps of producing the first layer spreading a mixture of the fibers and the binders on to a rotating carrier web to form a continuous fleece and compressing the continuous fleece in a continuous process an elevated temperature and accompanied by the activation of part of the binders to give a transportable-resistant fibrous mat. On this fibrous mat are placed the tangled fibers forming the covering layer in the form of a continuous, open tangled fiber fleece and the latter is connected to the fibers and/or the binders of the first layer by binders having an affinity therewith. The covering layer has a higher density than the first layer.

Abstract: Low density fibrous mats formed from fibres and thermosetting and thermoplastic binders, transformed by moulding at elevated temperatures are used for the production of mouldings. Such fibrous mats are produced in that a mixture of fibres and binders is spread out to form a fleece and the latter is compressed or compacted to a mat at high temperature. For the planned influencing of the characteristics of the moulding, while simultaneously reducing the binder requirement and the density, it is proposed that the fibrous mat or blanks thereof is passed through a pair of rollers with polished surfaces and by means of at least one roller binder is applied from the aqueous phase to the side of the fibrous mat facing the same under pressure action and that the fibrous mat is passed through the roller pair at a speed lower than the circumferential speed thereof and following onto the roller pair is passed through a drying zone.