Abstract: An essentially stable monomer miniemulsion characterized by small monomer droplet size is prepared and is then polymerized to a polymer latex under free radical polymerization conditions. The monomer miniemulsions herein include, in addition to water, a surfactant, and a monomer or mixture thereof, one or more polymers which function as a polymeric co-surfactant. The monomer miniemulsions are characterized by average monomer droplet size of 10 to 500 nanometers, preferably 80 to 150 nanometers. The amount of polymer added as a co-surfactant is about 0.5 to about 5 percent by weight based on monomer weight. The monomer emulsion may contain either a single monomer or a monomer mixture. The monomer emulsion is polymerized under conventional emulsion polymerization conditions yielding a polymer latex having an average polymer particle size of 10 to 500 nanometers, preferably 80 to 150 nanometers, and a narrow particle size distribution, i.e., a polydispersity index of about 1.05 to about 1.40.

Abstract: A composition of matter and a process for the preparation thereof is disclosed for a fibrous composite (e.g., synthetic wood). The fibrous composite contains 50 to 95% by weight carpet and 5 to 50% by weight of a structural adhesive. Structural adhesives effective in this application would include phenol-formaldehyde resins, either of the resole or novalac type, phenol-formaldehyde resins that have at least one other co-monomer present, e.g., bis-phenol A, resorcinol, and other substituted phenols, urea-formaldehyde resins, melamine urea formaldehyde resins, tannin-phenol-formaldehyde resins, diisocyanate resin, epoxy resins, crosslinkable polyvinyl acetate, proteins, e.g., soy flour, blood and polyester resins.