Shaped pulp article and resulting surface covering and method of making same

Abstract

A shaped pulp article and the method for making same are disclosed. The method of making a shaped pulp article includes the steps of preparing a slurry by mixing at least one material of construction with water, placing the slurry in a porous mold having a shaped molding surface, extracting excess water through the porous mold to form the shaped article, and pressing the shaped article between complementary heated male and female structures.

1 - 9 . (canceled) 
   
   
       10 . A casting mold comprising:
 a plurality of juxtaposed shaped pulp articles;   wherein the shaped pulp articles include at least one material of construction and water.   
   
   
       11 . A method of making a three-dimensional surface covering from at least one of pulp, paper and fiber including the steps of:
 preparing a slurry by mixing the at least one of pulp, paper and fiber with water;   placing the slurry in a porous mold having a shaped molding surface;   extracting excess water through the porous mold to form the shaped article;   dipping the shaped article in a second slurry mixture;   removing the shaped article from the second slurry mixture; and   pressing the shaped article between heated complementary male and female structures.   
   
   
       12 - 24 . (canceled)