Abstract: A heat stabilized, moldable, consolidated nonwoven panel resistant to shrinkage when molded during a subsequent thermoforming operation, said panel being substantially stiff and comprised of a nonwoven structure of reinforcement fibers admixed throughout and encapsulated by a thermoplastic resin formed from melted and compressed thermoplastic fibers having a melting point less than the melting point of said reinforcement fibers, said reinforcement fibers comprising 60-20 percent per volume of said panel and having a length of from 1-6 inches sufficient to enable said panel to achieve at least about 50 percent elongation during thermoforming.

Abstract: A method of making a moldable, nonwoven composite material. The method includes blending a mix of first fibers and second thermoplastic fibers. The second fibers have a melting point lower than that of the first fibers and comprise approximately 40-80 percent of the blend. The blend is then processed into a fibrous batt. The batt is then consolidated into a nonwoven structure with the first fibers being thoroughly intermixed with the second fibers. The nonwoven structure is then heated to a temperature below the melting point of the first fibers and above the melting point of the second thermoplastic fibers to substantially liquefy the second fibers and form a thermoplastic resin. The heated nonwoven structure is compressed to flow the liquefied resin to displace air voids in the nonwoven structure and encapsulate the first fibers. Finally, the nonwoven structure is cooled to form a composite material having substantially reduced air voids therein with the first fibers thoroughly encapsulated by the resin.

Abstract: A device for attaching thermoformed substrate material having front and back surfaces to a support frame. The device includes a fastener having a base portion and an attachment portion projecting from the base portion for engagement with the support frame. A nonwoven, needle-punched fiber sheet having first and second surfaces sandwiches the base portion between the first surface of the sheet and the back surface of the substrate. The sheet includes a central aperture having a width dimension sufficiently great to permit the attachment portion to project therethrough yet sufficiently narrow to enable the sheet to overlay the base portion. The sheet includes an enriched area of lower melting point fiber disposed proximate the first surface of the sheet and activatable to bond the first surface of the sheet to the back surface of the substrate without material flow and at a temperature utilized to thermoform the substrate material. This secures the base portion to the substrate material.