Process, composition and coating of laminate material

Abstract

A fibrous moldable substrate is provided having a fibrous material and a binder. The fibrous material and binder is subjected to heat such that only a portion of the binder is wetted to the fibrous material.

What is claimed is:  
     
         1 . A fibrous moldable substrate comprising: 
 a mat comprising a fibrous material and a binder;    wherein fibers of the fibrous material are randomly oriented; and    wherein the fibrous material and binder is subjected to heat such that only a portion of the binder is wetted to the fibrous material.    
     
     
         2 . The fibrous moldable substrate of  claim 1 , wherein the fibrous material is hemp.  
     
     
         3 . The fibrous moldable substrate of  claim 1 , wherein the fibrous material is kenaf.  
     
     
         4 . The fibrous moldable substrate of  claim 1 , wherein the fibrous material comprises hemp and kenaf.  
     
     
         5 . The fibrous moldable substrate of  claim 4 , wherein the fibrous material comprises about 50 weight percent hemp and 50 weight percent kenaf.  
     
     
         6 . The fibrous moldable substrate of  claim 1 , wherein the mat comprises about 25 weight percent hemp, about 25 weight percent kenaf and about 50 weight percent the binder.  
     
     
         7 . The fibrous moldable substrate of  claim 1 , wherein the binder is a thermomelt binder.  
     
     
         8 . The fibrous moldable substrate of  claim 7 , wherein the binder is polypropylene.  
     
     
         9 . The fibrous moldable substrate of  claim 1 , wherein the mat comprises about 24.75 weight percent hemp, about 24.75 weight percent kenaf, about 50 weight percent a polypropylene binder material and about 0.05 weight percent maleic anhydride.  
     
     
         10 . The fibrous moldable substrate of  claim 1 , wherein the mat is subjected to a compression force where its cross-section is reduced.  
     
     
         11 . The fibrous moldable substrate of  claim 1 , wherein the mat experiences insubstantial two-dimensional shrinkage while being subjected to the heat.  
     
     
         12 . The fibrous moldable substrate of  claim 1 , wherein the fibrous material is selected from a group comprising hemp, kenaf, flax and jute.  
     
     
         13 . A fibrous moldable substrate comprising: 
 a mat comprising a fibrous material and a binder;    wherein fibers of the fibrous material are randomly oriented;    wherein the fibrous material and binder is subjected to heat such that only a portion of the binder is wetted to the fibrous material; and    wherein the binder become dimensionally stable when cooled.    
     
     
         14 . The fibrous moldable substrate of  claim 13 , wherein the fibrous material is at least semi-rigid.  
     
     
         15 . The fibrous moldable substrate of  claim 12 , wherein the fibrous material is hemp.  
     
     
         16 . The fibrous moldable substrate of  claim 13 , wherein the fibrous material is kenaf.  
     
     
         17 . The fibrous moldable substrate of  claim 13 , wherein the fibrous material comprises hemp and kenaf.  
     
     
         18 . The fibrous moldable substrate of  claim 17 , wherein the fibrous material comprises about 50 weight percent hemp and 50 about weight percent kenaf.  
     
     
         19 . The fibrous moldable substrate of  claim 13 , wherein the mat comprises about 25 weight percent hemp, about 25 weight percent kenaf and about 50 weight percent the binder.  
     
     
         20 . The fibrous moldable substrate of  claim 13 , wherein the binder is a thermomelt binder.  
     
     
         21 . The fibrous moldable substrate of  claim 20 , wherein the binder is polypropylene.  
     
     
         22 . The fibrous moldable substrate of  claim 13 , wherein the mat comprises about 24.75 weight percent hemp, about 24.75 weight percent kenaf, about 50 weight percent a polypropylene binder material and about 0.05 weight percent maleic anhydride.  
     
     
         23 . The fibrous moldable substrate of  claim 13 , wherein the mat is subjected to a compression force where its cross-section is reduced.  
     
     
         24 . The fibrous moldable substrate of  claim 13 , wherein the mat experiences insubstantial two-dimensional shrinkage while being subjected to the heat.  
     
     
         25 . The fibrous moldable substrate of  claim 13 , wherein the fibrous material is selected from a group comprising hemp, kenaf, flax and jute.  
     
     
         26 . A fibrous moldable substrate comprising: 
 a mat comprising a fibrous material and a binder;    wherein fibers of the fibrous material are randomly oriented;    wherein the fibrous material and binder is subjected to heat such that only a portion of the binder is wetted to the fibrous material; and    wherein the mat is semipermeable when cooled.