Patent Publication Number: US-2007099524-A1

Title: Composite for a Panel Facing

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
      This application claims the benefit of provisional application No. 60/722,095 filed Sep. 29, 2006. 
    
    
     FIELD OF THE INVENTION  
      The present invention relates to a composite for a panel facing, and a structural panel on which the composite is assembled to provide a panel facing.  
     BACKGROUND  
      U.S. Pat. No. 6,743,742 discloses a panel having a nonwoven fibrous mat. The mat provides a permeable fibrous surface for adhering another material to the panel. The fibers of the mat are assembled to the panel, by being partially imbedded in a melt phase panel composition that flows to surround individual fibers of the mat. Thereafter, the panel composition is solidified to hold the fibers in place. However, the fibers can sink into the melt phase panel composition and become enveloped, particularly when the panel composition is of low viscosity. Further, the melt phase panel composition can wick among the fibers, particularly when the fibers are wetted by a panel composition of high wettability. Thus, the fibers at the panel surface tend to become enveloped by the panel composition, which reduces the number of fibers protruding from the panel composition for adhering another material to the panel.  
      The surface chemistry of the fibrous mat is considered to be phobic to either the melt phase panel composition, or to other materials that intend to adhere to the fibrous mat, when the materials have difficulty forming chemical bonds therebetween. For example, a fibrous mat of polyolefin composition, for example, polyethylene or polypropylene, will chemically bond to a panel composition of the same chemical family, while being phobic to many compositions that are not of the same chemical family. In turn, the surface chemistry of other materials that are intended to adhere to the fibrous mat is phobic to the polyolefin composition of the fibrous mat. A desirable fibrous mat would be capable of forming chemical bonds with materials of a different chemical family as that of the fibrous mat.  
      U.S. Pat. No. 4,242,406 discloses a structural laminate fabricated by applying a plastic finish coat against a mold, followed by applying a reinforcing layer having chopped glass mixed in a stream of fluid resin, and applying a bonding layer of glass fibers that are dry sprayed onto the fluid resin while the fluid resin is still tacky. The glass fibers are coated with a resin of the same chemical family as the fluid resin to promote adhesion therebetween. The glass fibers are intended to protrude from the fluid resin to become enveloped in an exterior layer of gypsum plaster that is sprayed or cast onto the protruding glass fibers. The structural laminate lacks a barrier layer to prevent the resin coated glass fibers from sliding into the fluid resin and become enveloped, particularly when the glass fibers are coated with a resin of the same chemical family as the fluid resin to promote adhesion therebetween. The glass fibers tend to become enveloped by the fluid resin, which reduces the number of fibers protruding from the fluid resin for adhering the gypsum plaster to the structural laminate.  
      In U.S. Pat. No. 5,624,386, a structural bar is reinforced by wrapping the bar with a flexible band having a first layer of fibers extending in one direction, and another layer of fibers extending in another direction. Further, the fibers in the flexible band are enveloped by a resin of high flexural modulus, which confines the fibers and prevents the fibers from protruding from the flexible band.  
      In U.S. Pat. No. 6,743,742, a panel is formed by solidifying a thermosetting, or thermoset, resin composition. Partially embedding a fibrous mat in a melt phase thermoset panel composition would encounter difficulties. The viscosity of the melt phase thermoset is difficult to control, because the viscosity disproportionately increases when its temperature moderately decreases. Thus, the melt phase of the thermoset is attained solely when accompanied by a low viscosity, or high melt index, which promotes sinking of the fibers into the resin composition. Further, the melt phase is known for its high wettability, which promotes wicking among the fibers of the mat. The fibers of the fibrous mat would tend to be enveloped by the melt phase thermoset, which resists the adherence of other materials to the panel.  
      To avoid enveloping the fibrous mat with the melt phase panel composition, it would be desirable to provide a composite having a fibrous mat on a barrier layer, such that, when the composite is assembled to a panel composition, the barrier layer is between the fibrous mat and the melt phase panel composition, wherein the barrier layer shields the fibrous layer from contact with the panel composition. The fibrous layer is exposed from the barrier layer and is available for adherence of other materials to the panel.  
      To overcome difficulties in adhering a panel composition to other materials, it would be desirable to provide a composite having a fibrous layer bonded to a side of a barrier layer, wherein the fibrous layer is chemically compatible with the other materials to bond to the other materials, and wherein at least the side of the barrier layer is impermeable to the panel composition and isolates the fibrous layer from contact or engagement with the panel composition.  
      Another desirable composite construction would have another, or farther fibrous layer bonded to another side of the barrier layer, wherein, the further fibrous layer is chemically compatible with the barrier layer and with the panel composition to bond with both the barrier layer and the panel composition.  
     SUMMARY OF THE INVENTION  
      According to an embodiment of the invention, a composite for assembly to a panel includes a fibrous layer bonded to a side of a barrier layer, wherein the barrier layer is impermeable to the chemical composition of the panel and isolates the fibrous layer and the fibers in the fibrous layer from contact with the panel composition such that the fibers of the fibrous layer are exposed from the side of the barrier layer and are free of the panel composition to adhere another material to the panel. Advantageously, the number of fibers available to adhere another material to the panel is not reduced by being enveloped in the panel composition. Further, the fibers are not limited to the same chemical family as that of the panel composition. Further, the fibers are not confined within a resin layer.  
      According to another embodiment of the invention, another fibrous layer is bonded to another side of the barrier layer, and is chemically compatible with the corresponding another side of the barrier layer and with the panel composition to bond with both the barrier layer and the panel.  
      Another embodiment of the present invention includes an open mesh scrim bonded to the barrier layer.  
      Further, according to the invention, a method of making a panel, includes, fabricating a composite for a panel facing having a fibrous layer bonded to a barrier layer; and imbedding at least partially the barrier layer in a panel composition of the panel, wherein the barrier layer separates the panel composition from the fibrous layer to prevent engagement therebetween, and at least a portion of the fibrous layer is exposed from the barrier layer and is free of the panel composition to adhere other materials to the panel.  
      According to a further embodiment of the invention, a panel includes, a polymeric resinous panel composition; and a composite for a panel facing comprised of, a barrier layer and at least one fibrous layer to adhere other materials to the panel, wherein, the barrier layer is between the fibrous layer and the panel composition, the fibrous layer is bonded to the barrier layer, and fibers in the fibrous layer have portions thereof at least partially exposed from the barrier layer and is free of the panel composition to adhere other materials to the panel. Advantageously, the fibrous layer and the resinous composition of the panel substrate are separated by the barrier layer therebetween, such that, the barrier layer prevents contact between the fibrous layer and the resinous composition.  
      According to another embodiment of the invention, a composite includes, a barrier layer having an extruded first layer of a first thermoplastic composition on one side and an extruded second layer of a second thermoplastic composition on another side, a first fibrous layer covering the first layer and melt bonded to the first thermoplastic composition, and a second fibrous layer covering the second layer and melt bonded to the second thermoplastic composition.  
      These and other embodiments of the invention will now be described by way of example with reference to the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1A  is an enlarged cross section view of a portion of a composite.  
       FIG. 1B  is a fragmentary view of a portion of  FIG. 1A .  
       FIG. 2  is a cross section view of another embodiment of a composite  
       FIG. 3  is a cross section view of another embodiment of a composite  
       FIG. 4  is a cross section view of another embodiment of a composite  
       FIG. 5  is a schematic view of an apparatus for making a curvilinear composite.  
       FIG. 6  is a schematic view of a curvilinear composite with parts broken away.  
       FIG. 7  is a fragmentary section view of an embodiment of an attached composite.  
       FIG. 8  is a fragmentary section view of another embodiment of a composite.  
       FIG. 9  is a fragmentary section view of yet another embodiment of a composite.  
       FIG. 10  is a fragmentary section view of yet another embodiment of a composite. 
    
    
     DETAILED DESCRIPTION  
       FIG. 1A  discloses an embodiment of a flexible or rigid composite  2 .  FIG. 1A  further discloses an exemplary panel  100  on which the composite  2  is assembled to provide a panel facing. The composite  2  has at least one exemplary fibrous layer  102  melt bonded to, and covering, an outer side of an exemplary barrier layer  104 . An inner side of the barrier layer  104  faces toward a polymeric panel composition  108  that comprises a panel substrate to which the composite  2  is melt bonded. The barrier layer  104  is selected with a polymer composition capable of forming a melt bond with the polymeric panel composition  108 . According to an embodiment of the invention, the panel composition  108  has a surface when in melt phase forms a melt bond with the composite  2 . Thereafter, the surface of the panel composition  108  solidifies to retain the composite  2  in place.  
      A melt bond is formed at the interface of two, chemically compatible materials, wherein one of the materials comprises a polar ionized composition with a melt phase surface, and the other of the materials in solid phase has a surface, alternatively a partially melted surface, with the capability to form covalent chemical bonds with the melt phase surface of the polar ionized composition. The melt phase surface is then solidified to a solid phase to form a solidified melt bond that affixes or retains the two chemically compatible materials.  
      A melt bond is formed in an alternative manner at the interface of two, chemically compatible materials, when one of the materials has a melt phase surface, and the surface of the second material in solid phase is of low phobicity to the adherent macromolecular morphology formed by the melt phase surface. Alternatively, a partially melted surface is formed on the second material in solid phase, and is of similar low phobicity. The melt phase is then solidified to a solid phase, by complete polymerization, solvent drying or cooling, as appropriate according to the chemical composition being solidified from the melt phase, to form a solidified melt bond between the two materials.  
      The melt phase referred to herein comprises; a fluent thermoplastic composition at a temperature above its melt temperature, or fluent thermoset composition in a prepolymerized melt phase at a temperature above its melt temperature. The melt temperature further refers to a glass transition temperature of a crystalline polymeric composition. The melt phase includes, but is not limited to, a prepolymerized melt phase, a heat induced melt phase or a chemically induced melt phase. A prepolymerized melt phase refers to a thermoset resin composition or a thermoplastic resin composition dissolved in a compatible solvent prior to complete polymerization of the composition. A heat induced melt phase refers to a thermoplastic composition in solid phase to which heat is applied to heat the surface of the composition at least to its melt temperature to provide a melt phase surface.  
      According to an embodiment of the invention, the barrier layer  104  is chemically compatible with the panel composition  108  and with the fibers of the fibrous layer  102  to form respective melt bonds therewith. According to another embodiment, a chemically compatible adhesive material forms a melt bond at the interface between the barrier layer  104  and the panel composition  108 , and/or a melt bond at interface of the barrier layer  104  and the fibers of the fibrous layer  102 .  
      In another preferred embodiment of the invention, the surface of the barrier film  104  is heated at least to its melt temperature to result in a heat induced melt phase surface to melt bond with the fibers of the fibrous layer  102 . The fibrous layer becomes melt bonded to the barrier film  104  when the melt phase surface is solidified by cooling below its melt temperature, which retains the fibrous layer  102  in place. The description herein refers to additional melt bonded structures, which are similarly fabricated.  
      A chemically induced melt phase refers to a thermoplastic composition in solid phase to which a compatible solvent is applied to produce a melt phase. In another preferred embodiment of the invention, the surface of the barrier film  104  is dissolved in a compatible solvent to produce a melt phase surface in the solvent. The fibrous layer  102  forms a chemically compatible bond with the melt phase surface. Alternatively, the solvent comprises an optional dissolved adhesive to increase the bond strength. The fibrous layer  102  becomes melt bonded to the barrier film  104  when the melt phase surface is solidified, by drying to drive off the solvent, which retains the fibrous layer  102  in place. The fabrication processes described herein apply similarly to the fabrication of other melt bonded structures to be described.  
      At least portions of fibers in the fibrous layer  102  are exposed from a side of the barrier layer  104  that faces away from the panel composition  108 , and are free of contact with the panel composition  108  to be available for adhering another material to the panel  100 . The fibrous layer  102  is permeable to another material intended to be assembled by adherence to the panel  100 . Advantageously, the chemical composition of the fibrous layer  102  is selected for being chemically compatible with another material intended to adhere to the panel  100 , to form a chemical bond therewith. Examples of such materials are disclosed herein.  
      Another embodiment of the composite  2  has two exemplary fibrous layers  102 ,  106  disposed against and melt bonded to opposite sides of the barrier layer  104  therebetween.  FIG. 1A  discloses a preferred embodiment of the invention wherein the fibrous layer  106  is melt bonded against a side of the barrier layer  104  that faces toward the panel composition  108 . According to an embodiment of the composite  2 , each of the fibrous layers  102 ,  106  comprises a mat of fibers covering the corresponding side of the barrier layer  104 . The fibers of the fibrous layer  102  or  106  are nonwoven with a basis weight range of 10-200 gm/m 2  for example. The fibers extend lengthwise in a direction substantially along the major axis of the respective fibrous layers  102 ,  106 . Further, the fibers are selected from the group consisting of, thermal bonded or chemically bonded carded web, thermally bonded or chemically bonded spun web, and wet laid. Further, the fibers of the fibrous layer  102  or  106  includes, but is not limited to, fiberglass or thermoset fibers, such as, polyester fibers, or a mixture of fiberglass or thermoset fibers and thermoplastic fibers, wherein the thermoplastic fibers is rendered to a heated melt phase state to enhance joining of the thermoset fibers against one side of the barrier layer  104  by melt bonding. For example, polyethylene terephthalate (PET) fibers mixed with polypropylene (PP) fibers, use melted PP fibers to bond with the PET fibers and compatibly bond with a thermoplastic or thermoset barrier layer  104 , which joins the PP fibers and the PET fibers to one side of the barrier layer  104  and provide a fibrous layer  102  or  106 .  
      According to an embodiment wherein the fibrous layer  106  is not present on an inner side of the barrier layer  104 , the panel composition  108  forms a melt bond with the inner side of the barrier layer  104  that faces toward the panel composition  108 . The barrier layer  104  partially imbeds in the surface of the panel composition  108  without being enveloped by the panel composition  108 . However, when the fibrous layer  106  is present, as shown in  FIGS. 1 and 1 A, the fibrous layer  106  and the fibers thereof are substantially enveloped by the panel composition  108  except where the fibers melt bond with the barrier layer  104 . According to an embodiment of the invention, the enveloped fibrous layer  106  reinforces the panel composition  108 . Further, an embodiment of invention includes the melt bond being enhanced by internal pressure due to optional swelling of the fibrous composition of said one of the fibrous layers  106  while being enveloped by the panel composition  108  in a melt phase or melt state. Further, whether or not the fibrous layer  106  is present, the barrier layer  104  is impermeable to the melt phase, panel composition  108 . Advantageously, the barrier layer  104 , being impermeable, separates the panel composition  108  from the other fibrous layer  102 , thereof such that the fibrous layer  102  is isolated or separated from the panel composition  108  to prevent contact therebetween. Further, the fibers in the fibrous layer  102  are exposed from the corresponding other side of the barrier layer  104  and are free of contact with the panel composition  108  to adhere other materials to the panel  100 , to be described, hereinafter.  
      A preferred panel composition  108  comprises a polymeric resinous composition in a melt phase that envelops and melt bonds with the fibrous layer  106  when present, or that melt bonds with the barrier layer  104  when the fibrous layer  106  is absent. Desirably, a melt bond is formed at an interface of the chemically compatible barrier layer  104  and the fibrous layer  102 . Further, a melt bond is formed at an interface of the chemically compatible barrier layer  104  and fibrous layer  106 . According to the embodiment disclosed by  FIG. 1A , the exemplary fibrous layer  102  is chemically compatible with the exemplary barrier layer  104  to form a melt bond therewith. The exemplary fibrous layer  106  is chemically compatible with the exemplary barrier layer  104  to form a melt bond therewith. The exemplary fibrous layer  106  is chemically compatible with the panel composition  108  to form a melt bond therewith. In an embodiment in which the exemplary fibrous layer  106  is absent, the exemplary barrier layer  104  is chemically compatible with the panel composition  108  to form a melt bond therewith.  
      The panel  100  is manufactured by applying the composite  2  against the panel composition  108  in a melt phase, one on the other, and horizontally or vertically against each other. In an alternative embodiment, the panel composition  108  comprises an applied coating that melt bonds with, and completely covers, said one of the fibrous layers  106 , and has a thickness that extends beyond the thickness of the fibrous composition of said one of the fibrous layers  106 . The panel composition  108  comprises, either a thermoset polymeric composition  108  including crystalline polymers in a prepolymerized melt phase, or a thermoplastic polymeric composition having at least its surface in melt phase, wherein the melt phase surface is heat induced or chemically induced by a solvent or by an adhesive at the interface with the composite  2 . For example, a barrier layer  104  of higher melt temperature compared to the panel composition  108  is impermeable to the melt phase panel composition  108  that is heated to a melt phase. Pressure is applied to embed the fibrous layer  106  in the melt phase surface of the panel composition  108 , and/or to partially embed the barrier layer  104  in the melt phase surface of the panel composition  108  when the fibrous layer  106  is absent. The panel composition  108  permeates and substantially envelopes the fibrous layer  106  when present. Further, said one of the fibrous layers  106  reinforces the panel composition  308 . Further, the bond is enhanced by optional swelling of the fibrous composition of said one of the fibrous layers  106  within the panel composition  308 . The barrier layer  104  is impermeable to the panel composition  108  and prevents contact between the panel composition  108  and the fibrous layer  102 .  
      The thermoplastic polymeric panel composition  108  comprises substantially polypropylene, polyethylene, polyurethane, polystyrene, polyamide, polyester and copolymers thereof and amorphous crystalline polymers. Further additives include fibrous reinforcements, fillers and foam bubbles. The panel composition  108  comprises a solidifiable, melt phase resin of a thermoset or thermoplastic, consisting of, but not limited to, unsaturated polyester, epoxy or polyurethane. The liquid resin may contain reinforcement fibers, fillers and a foaming agent, such as air or chemical foaming agent. The resin wicks into one of the resin permeable fibrous layers  106  and permeates the same, as well as, permeates the scrim  310  when the scrim  310  is present. A thermosetting resinous composition  108  includes, but is not limited to, unsaturated polyester resins with or without styrene monomer as a reactive diluents, vinyl ester resins with or without reactive diluents, epoxy resins including catalyst and/or a complimentary reactive component or a Novolac® epoxy and high temperature epoxy and variants, phenolic resins including phenol-formaldehyde, urea formaldehyde resins, urethane resins, unsaturated acrylate resins, unsaturated methacrylate resins or siloxane resins. Examples of unsaturated polyesters include, but are not limited to, unsaturated orthophthalate polyester, unsaturated isophthalate polyester and unsaturated aliphatic polyester. Examples of urethane resins include, but are not limited to, aliphatic or aromatic isocyanate based (Component A) combined with polyester or polyether polypropyl based (component B), or isocyanurate type (high ratio of A:B).  
      A thermoplastic resinous composition  108  includes, but is not limited to, polyester resins, polypropylene resins, polyethylene reins, polyamide resins, polystyrene resins, acrylic resins, methacrylic resins, polyvinyl chloride resin, and copolymers thereof. Examples of polyesters include, but are not limited to, polyethylene terephthalate, polyethylene adiapate, polybutylene terephthalate, polycaprolactone, polylactic acid or polycarbonate. Examples of polypropylenes include, but are not limited to, isotactic polypropylene, syntactic polypropylene, amorphous polypropylene, ethylene propylene copolymer, acid modified polypropylene, or ethylene propylene diene monomer (EPDM). Examples of polyethylenes include, but are not limited to, linear low density polyethylene, high pressure low density polyethylene, medium density polyethylene, high density polyethylene and ethylene copolymers. Examples of ethylene copolymers include, but are not limited to, ethylene vinyl acetate (EVA) or ethylene acrylic acid (EEA). Examples of polyamides include, but are not limited to, Nylon 106™, Nylon 106, 106™, Nylon 106, 10™, Nylon 11™ and Nylon 12™. Examples of polystyrene include, but are not limited to: homopolymers, copolymers/terpolymers, such as, acrylonitrile-butadiene-styrene (ABS), or styrene-maleic anhydride (SMA).  
      Permeation of a corresponding fibrous layer  106  is readily accomplished by thermosetting polymers, which comprise low viscosity monomers or oligomers. Permeation of a corresponding fibrous layer  106  is readily accomplished by thermoplastic monomers of sufficient molecular weight to be liquids or solids at ambient temperature, such as, methyl methacrylate and caprolactone. High pressure molding may be used to promote permeation of a corresponding fibrous layers  106  by one of many thermoplastic polymers having relatively high viscosities while in the melt stage, such as, polyethylene and polypropylene. Alternatively, lower molecular weight (m.w.) surface regions, on volatile monomer based polymers having relatively high viscosity, can permeate a corresponding fibrous layer  102  or  106 . For example, a surface layer of ethylene acrylic acid copolymer (EAA) of relatively low m.w. on a polyethylene layer can permeate the corresponding fibrous layer  102  or  106 . Further, alternatively, fluorinated polymers comprise a thermoplastic, such as a fluoroethylene polymer (FEP) and non-thermoplastic polymers, such as, polytetrafluorethylene (PTFE). While PTFE is used, the PTFE is pulverized and dispersed in a fluid, and subsequently sintered to form a substantially continuous resinous panel composition  108 .  
      According to one preferred embodiment, a panel  100  is fabricated with a thermoplastic panel composition  108 , including, but not limited to, polypropylene, polyurethane, polystyrene, polyamide, polyester, polyolefin, such as, polyethylene (PE), polypropylene (PP), and copolymers thereof, polyvinyl chloride (PVC), polystyrene, and polyamide, such as, uncured nylon. Further, the composition  108  is air entrained or foamed. Further, the composition  108  is reinforced with fibers. Further the composition  108  is treated with one or more active reagents or non-reactive agents serving as, a filler, colorant, fire retardant, biocide, or fluid repellant.  
      According to an embodiment, the barrier layer  104  comprises an impermeable solid film. According to another embodiment, should the barrier layer  104  be rendered to a melt phase while being in contact with the melt phase panel composition  108 , the barrier layer  104  has a high viscosity, i.e. a low melt index (MI) or low melt flow rate (MFR), which avoids permeation by wicking or otherwise flowing of the melt phase panel composition  108  through the barrier layer  104 . Alternatively, the barrier layer  104  comprises a microporous film having pores that are too narrow to wick the melt phase panel composition  108 . For example, the composition of the microporous barrier layer  104  includes, but is not limited to, PP film, sPP film, EPR film, or nonwoven PP/PET core/sheath. Accordingly, at least the side of the microporous barrier layer  104  on which the fibrous layer  102  is bonded is impermeable to the melt phase panel composition  108 , which prevents engagement or contact between the panel composition  108  and the fibrous layer  102 .  
      According to one preferred embodiment of a manufacturing method, the composite  2  is assembled onto a melt phase surface of the panel composition  108 . The melt phase surface of the panel composition  108  is formed during manufacture of the panel  100  by spreading out a layer of the prepolymerized panel composition  108 . Alternatively, the melt phase surface is formed by surface heating the panel  100  to its thermoplastic melt temperature, or by solvent chemical activation or adhesive chemical activation. Alternatively, the barrier layer  104  of the composite  2  is rendered at least partially to the melt phase state, for example, by surface heating to its thermoplastic melt temperature, or by solvent chemical activation or adhesive chemical activation. The composition  108  and the barrier layer  104  of the composite  2  are melt bonded to combine the two compositions by applying pressure while one or the other, or both, are in corresponding melt phase states. The composition of the barrier layer  104  and the composition of the panel composition  108  are chemically compatible to form a melt bond upon cooling to solidify the melt phase state compositions.  
      Upon solidifying the melt phase panel composition  108  while being bonded to one side of the barrier layer  104 , for example, by appropriate cooling to ambient temperature, or by appropriate dissipation of the solvent or chemical activation composition, the two compositions become intimately bonded together, such that the composite  2  serves as a facing for the panel  100 , and the fibrous layer  102  thereof, on another side of the barrier layer  104  is shielded by the barrier layer  104  from being permeated by the melt phase panel composition  108 . Further, the fibrous layer  102  thereof, is free of the melt phase panel composition  108 , and comprises an adhesion promoting, permeable fibrous layer  102  for adhering another material  700 ,  FIGS. 7-9 , to the panel  100 . The panel composition  108  is then solidified from a melt phase to a solid phase by solvent drying, complete polymerization or cooling, as appropriate, to retain in place the composite  2 . Embodiments of the composite  2  disclosed herein comprise layers  102 ,  104  and  106  that are chemically compatible to form melt bonds at their abutting interfaces. Further, the panel composition  108  is chemically compatible with the barrier layer  104  or the fibrous layer  106  when present to form melt bonds therewith. Further, the fibrous layer  102  has a fibrous layer composition selected for establishing a chemical bond with other materials  700  intended for adherence to the panel  100 .  
      According to an embodiment of the invention in  FIG. 1A , the panel composition  108  permeates said one of the fibrous layers  106 , such that the thickness of the panel composition  108  is sufficient to permeate and fully encase or envelope the fibers of said one of the fibrous layers  106 . As disclosed by  FIG. 1B , the panel composition  108  extends beyond the projecting fibers  106   a  at the surface of said one of the fibrous layers  106 . The panel composition  108  has a roughened, panel surface  107  covering the fibrous composition, due to the presence of the fibers of the fibrous layer  106  near the panel surface  107 . For example, the roughened, panel surface  107  provides a non-skid surface, or a low gloss, matte finish surface, on the panel  100 .  
      The embodiment of a composite  2  disclosed by  FIG. 1A  is exemplary of all embodiments of a composite  2 , as disclosed herein. Similarly, the barrier layer  104  and the fibrous layer  102  disclosed by  FIG. 1A  are exemplary embodiments of a barrier layer and a fibrous layer in each of the embodiments of a composite  2 , as disclosed herein. Similarly, the fibrous layer  106  disclosed by  FIG. 1A  is an exemplary embodiment of a fibrous layer in all embodiments of a composite  2 , as disclosed herein, for bonding with a panel composition, as disclosed herein.  
       FIG. 2  discloses another embodiment of a panel  200  fabricated with a flexible or rigid composite  2  that provides a facing for the panel  200 . The composite  2  has at least two penneable fibrous layers  202 ,  206  bonded to, and against opposite sides of a barrier layer  204  therebetween. Further the panel  200  comprises, a resinous panel composition  208  bonded to said one of the fibrous layers  206  of the composite  2 . Various embodiments of the fibrous layers  202 ,  206 , barrier layer  204  and resinous panel composition  208  are similar to the corresponding, various embodiments of the fibrous layers  102 ,  106 , barrier layer  104  and resinous panel composition  108 . In addition, the panel composition  208 , in  FIG. 2 , is thicker, compared to the composition  108  disclosed by  FIG. 1A , so as to extend substantially beyond said one of the fibrous layers  206 . The thicker panel composition  208 , when solidified, forms a panel surface  207  that covers and extends beyond said one of the fibrous layers  206 . The panel surface  207  on the panel composition  208  is formed with a desired surface finish or surface texture.  
      Advantageously, the barrier layer  204  separates the panel composition  208  from the other fibrous layer  202  thereof, that is against another side of the barrier layer  204 , such that the fibrous layer  202  thereof, is isolated from contact with the panel composition  208 . Further, portions of the fibers in the fibrous layer  202  are exposed from the other side of the barrier layer  204  and are free of the panel composition  208  to adhere another material  700 .  
      Another embodiment of the invention is obtained by the composite  2  having the fibrous layer  202  and the barrier layer  204 , without the fibrous layer  206 . The composite  2  serves as a panel facing, by imbedding the barrier layer  204  at least partially in the surface of the melt phase panel composition  208 . Further, the partially imbedded barrier layer  202  and the panel composition  208  are melt bonded.  
       FIG. 3  discloses another embodiment of a panel  300  fabricated with a flexible or rigid composite  2  having at least two permeable fibrous layers  302 ,  306  against, and melt bonded to, a barrier layer  304  therebetween. Further, the composite  2  has a scrim  310  against the barrier layer  104 . The scrim  310  prevents shrinking or warping of the fibrous layers  302 ,  306  as they undergo strain under the stresses applied by manufacturing operations. The scrim  310  is an open mesh, having woven or nonwoven yarns melt bonded to one side of the barrier layer  304 .  
      One of the fibrous layers  306  extends into openings between spaced apart yarns of the scrim  310 , and is melt bonded to and against the barrier layer  304 . The fibrous layer  306  bonds the scrim  310  to the barrier layer  304 . Alternatively, the scrim  310  itself is melt bonded to the barrier layer  304 . Further, said one of the fibrous layers  306  of the composite  2  is melt bonded to a resinous panel composition  308 . Preferably, the panel composition  308  permeates said one the permeable fibrous layers  306  and the scrim  310 , to fully encase and envelope the fibrous layer  306  and the scrim  310 . Alternatively, the scrim  310  is melt bonded to the other side of the barrier layer  304  from the panel composition  308 , such that, the fibrous layer  302  extends into the openings of the scrim  310 , and is melt bonded to and against the barrier layer  304 .  
      According to an embodiment disclosed by  FIG. 3 , the thiclness of the panel composition  308  fully encases or envelopes the fibrous layer  306 , similar to the previously described panel composition  108  that encases and envelopes the fibrous layer  106 , according to  FIG. 1B . When the scrim  310  is present, the thickness of the panel composition  308  is increased sufficiently to permeate, and fully encase and envelope, the scrim  310  and said one of the fibrous layers  306 . The panel composition  308  has a roughened panel surface  307  covering the fibrous composition near the surface  307  of the panel composition  308 , similar to the previously described, roughened surface  107  as disclosed by  FIG. 1B .  
      Advantageously, the barrier layer  304  separates the panel composition  308  from the other fibrous layer  302  thereof, against another side of the barrier layer  304 , such that the fibrous layer  302  thereof, is isolated from contact with the panel composition  308 . Further, at least portions of the fibers in the fibrous layer  302  are exposed from the other side of the barrier layer  304  and are free of the panel composition  308  to adhere another material  700 .  
      Another embodiment of the invention is obtained by the composite  2  having the fibrous layer  302  and the barrier layer  304 , without the fibrous layer  306 . The composite  2  serves as a panel facing, by imbedding the barrier layer  304  at least partially in the melt phase panel composition  308 , and the panel composition  308  melt bonds to the partially imbedded barrier layer  302 . At least a portion of the fibrous layer  302  is exposed from the barrier layer  304  to assist in adherence of another material  700 .  
       FIG. 4  discloses another embodiment of a panel  400  fabricated with a flexible composite  2  having at least two permeable fibrous layers  402 ,  406  against, and bonded to, a barrier layer  404  therebetween. Further, the composite  2  has a scrim  410  against the barrier layer  404 . The fibrous layer  406  bonds the scrim  410  to the barrier layer  404 . Further the panel  100  comprises, a resinous panel composition  408  bonded to, and fully encapsulating, said one of the fibrous layers  406  of the composite  2 . Preferably, the panel composition  408  permeates said one the permeable fibrous layers  406  and the scrim  410 , fully encasing and encapsulating the fibrous layer  406  and the scrim  410 . One of the fibrous layers  406  extends into openings between spaced apart yarns of the scrim  410 , and is melt bonded to and against the barrier layer  404 . The fibrous layer  406  bonds the scrim  410  to the barrier layer  404 . Alternatively, the scrim  410  itself is melt bonded to the barrier layer  404 . Further, said one of the fibrous layers  406  of the composite  2  is melt bonded to a resinous panel composition  408 . Preferably, the panel composition  408  permeates said one the permeable fibrous layers  406  and the scrim  410 , to fully encase and envelope the fibrous layer  406  and the scrim  410 . Alternatively, the scrim  410  is melt bonded to the other side of the barrier layer  404  from the panel composition  408 , such that, the fibrous layer  402  extends into the openings of the scrim  410 , and is melt bonded to and against the barrier layer  404 .  
      Another embodiment of the invention is obtained by the composite  2  having the fibrous layer  402  and the barrier layer  404 , without the fibrous layer  406 . The fibrous layer  402  bonds the scrim  410  to the barrier layer  404 . The composite  2  serves as a panel facing, by imbedding the barrier layer  404  at least partially in the melt phase panel composition  408 , and the panel composition  408  melt bonds to the partially imbedded barrier layer  402 . At least a portion of the fibrous layer  402  is exposed from the barrier layer  404  and is free of the panel composition  408  to adhere another material  700 .  
      Various embodiments of the fibrous layers  402 ,  406 , barrier layer  404 , scrim  410  and resinous panel composition  408  are similar to the various embodiments of the fibrous layers  302 ,  306 , barrier layer  304 , scrim  310  and resinous panel composition  308 . hI addition, the panel composition  408  is substantially thicker than the resinous panel composition  308 . The thicker panel composition  408 , when solidified, forms a panel surface  407  that extends beyond the thiclness of the fibrous composition of said one of the fibrous layers  406 . The panel surface  407  on the panel composition  408 , is formed with a desired surface finish or surface texture, to be described hereinafter.  
       FIGS. 3 and 4  disclose the scrim  310  and  410 , respectively, melt bonded to said one side of the barrier layer  304 ,  404 , respectively. Alternatively, the scrim  310 ,  410  is melt bonded to the other side of the barrier layer  304 ,  404  from the panel composition  308 ,  408 . Further, one side or both sides of the barrier layer  304 ,  404  can have respective scrims  310 ,  410  bonded thereto.  
      According to an embodiment of the invention, the composite  2  comprises a barrier layer  104  and a fibrous layer  102  applied one on the other, wherein the fibrous layer  102  comprises glass fibers or fiberglass. According to another embodiment each of the fibrous layers  102 ,  106  comprises glass fibers or fiberglass applied one on the other with the barrier layer  104 . The fiberglass of the fibrous layer  102  melt bonds to a melt phase polymeric barrier layer  104 , and farther establishes a bond with a melt phase material  700  intended for adherence to an exemplary panel  100 . Each of the barrier layer  104  and the material  700  comprises a wide variety of thermoplastic or thermoset, melt phase polymeric compositions. The composition of the barrier layer  104  is selected to be chemically compatible to form a melt bond with the melt phase composition  108  of the panel  100 . The surface chemistry of fiberglass is of low phobicity to the adherent macromolecular morphology formed by a melt phase surface of the polymeric compositions. The fiberglass fibrous layer  102 ,  106  has a higher melt temperature than the polymeric compositions, and is insoluble in solvents of such polymeric compositions, while being chemically compatible to melt bond with the melt phase of the polymeric compositions.  
      According to another embodiment of the invention, the composite  2  comprises a barrier layer  104  and a fibrous layer  102  applied one on the other, wherein the fibrous layer  102  comprises a polymeric material having a higher melt temperature than a polymeric material of the barrier layer  104 . The surface of the barrier layer  104  is heated to form a melt phase surface that is chemically compatible with the fibrous layer  102  to melt bond therewith. For example, a fibrous layer  102  of unsaturated polyester composition forms a melt bond with a melt phase surface of a barrier layer  104  of polypropylene.  
      Another embodiment of a composite  2  is manufactured, for example, by extruding a polyurethane barrier layer  104 . The barrier layer  104  is chemically compatible with fibrous layers  102  and  106 , one of which comprises polyester fibers, and the other of which comprises polypropylene fibers melt bonded to the barrier layer  104 . The barrier layer  104  of polyurethane has a higher melt temperature that either of polyester or polypropylene. The surface of the barrier layer  104  is heated at least to the melt temperature of polyester to form a melt bond with the polyester fibers. Afterward, the other surface of the barrier layer  104  is heated at least to the melt temperature of polypropylene to form melt bonds with the polypropylene fibers. Accordingly, a the fibrous layer  102  or  106  that has a higher melt temperature of polyester, for example, is heated and melt bonded to a corresponding side of the barrier layer  104 , to form a previously bonded layer, followed by heating and melt bonding the fibrous layer  102  or  106  at a lower melt temperature of polypropylene, for example, to an opposite corresponding side of the barrier layer  104  to form a subsequently bonded layer.  
      According to another embodiment of the invention, a bicomponent, exemplary barrier layer  104  is fabricated by a coextrusion process comprising, extruding a melt phase thennoplastic or thermoset having a higher melt temperature, for example, polyurethane, to form a first side of the barrier layer  104 , while extruding a melt phase thermoplastic of lower met temperature, for example, a polyolefin, such as, polypropylene, to form a second side of the barrier layer  104 , which sides are melt bonded by the coextrusion process, and which become melt bonded together to form a composite barrier layer  104  comprised of two layers.  
      According to an embodiment of the invention the composite  2  has a fibrous layer  102  comprised of polyester fibers. The polyester fibers are melt bonded to the polyurethane side of the barrier layer  104 . For example, the surface of the polyurethane side is heated to form a melt surface, without melting the entire thickness of the polyurethane side. The polyester fibers are deposited on the melt surface of the polyurethane side to melt bond therewith. According to an embodiment of the invention, the polyester fibers serve as the fibrous layer  102  when the polypropylene side of the barrier layer  104  is selected to melt bond directly to a melt phase panel composition  108  of an exemplary panel  100 .  
      Embodiments of the polyurethane composition include, a polymer produced by a reaction of polyisocyanates with polyester-based or polyether-based resins, to produce either a thermoplastic or a thermosetting polyurethane composition. A thermoplastic polyurethane composition is preferred. Embodiments of polyolefin compositions include, but are not limited to; polymers and copolymers of, polypropylene, polyethylene, ethylene-vinyl acetate ionomer, polybutylene, and polymethylpentene. The polyurethane composition is chemically compatible with polyester to form a melt bond therewith. The melt bond can form at the melt temperature of a polyolefin, for example, polypropylene, and below the higher melt temperature of the polyurethane composition. The polyurethane material has a higher melt temperature than the unsaturated polyester composition. The surface of the polyurethane film is heated at least to the melt temperature of the polyester fibers of the fibrous layer  102  or  106  to the melt temperature of the polyester fibers to melt bond the fibers to the polyurethane film surface. Advantageously, the polyurethane composition of higher melt temperature than the fibers to remain as an impermeable barrier layer  104  without forming voids through the thickness of the barrier layer  104 . The polyurethane composition, whether thermosetting or thermoplastic, is chemically compatible with the melt phase polyester composition to form a melt bond therewith. According to an alternative embodiment, when the polyurethane is a thermoplastic, the surface of the polyurethane is heated to a tacky viscosity to further enhance fusing to the fibers, without forming voids through the thickness of the polyurethane film layer.  
      According to another embodiment of the invention, the fibrous layer  102  comprises polypropylene fibers melt bonded to a polypropylene side of the barrier layer  104 . The surface of the polypropylene side of the barrier layer  104  is heated at least to its melt temperature to form a melt surface, without melting the entire thickness of the polypropylene side. The polyurethane side of the barrier layer  104  has a higher melt temperature and does not melt while melt bonding the polypropylene fibers to the polypropylene side of the barrier layer  104 . According to an embodiment of the invention, the polypropylene fibers serve as the fibrous layer  102  when the polyurethane side of the barrier layer  104  is selected to melt bond directly to a melt phase panel composition  108  of an exemplary panel  100 .  
      According to an embodiment of the invention the composite  2  has one of the fibrous layers  102  or  106  comprised of polyester fibers and the other of the fibrous layers  102  or  106  comprised of polypropylene fibers.  
      After the polyester fibers of one of the fibrous layers  102  or  106  have been melt bonded to the polyurethane side of the barrier layer  104 , the surface of the polypropylene side of the barrier layer  104  is heated at least to the melt temperature of polypropylene to form a melt surface. The polypropylene fibers of the other of the fibrous layers  102  or  104  are deposited on the melt surface to melt bond therewith. The polyurethane side of the barrier film  104 , as well as, the polyester fibers have a higher melt temperature than that of the polypropylene side of the barrier layer  104  and do not melt when melt bonding the polypropylene fibers.  106 .  
      Advantageously, the fibrous layers  102  and  106  on the same composite  2  are of different chemical families, such that they are interchangeable one with the other to attain chemical compatibility with a panel composition  108  and chemical compatibility with another material  700 . Thus, the composite  2  solves a problem wherein the panel composition  108  is difficult to bond with another material  700  of a different chemical family.  
      When an embodiment having a scrim  310  is desired, the scrim  310  is fabricated as an open mesh having woven or nonwoven strands. The scrim  310  is added, preferably against the polypropylene layer of the barrier layer  104 , such that the polypropylene layer melts and fuses to the scrim  310 . Further, the polypropylene fibrous composition covers the scrim  310 , and further, extends through openings in the scrim  310  to register against the polypropylene layer of the barrier layer  104 . The polypropylene fibrous composition melts and fuses to the polypropylene film of the barrier layer  104 , and to the scrim  310 , as well. The scrim  310  has a melt temperature higher than that of polypropylene. In other embodiments, for example, the scrim  310  comprises polyester strands or fiberglass strands, which are of higher melt temperature and higher tensile strength or elastic modulus than polypropylene. For example, a scrim  310  in each embodiment hereof, is fabricated as an open mesh of strands of polyester or fiberglass, that is woven, nonwoven, or knit, with a binder of a thermoplastic or thermoset resinous coating serving to adhere the strands together and/or to adhere the scrim  310  against one side of the barrier layer  104 . The scrim composition is selected to be chemically compatible with the composition of the barrier layer  104  to form a melt bond therewith, and/or with the corresponding fibrous layer  102  or  104  to form a melt bond therewith.  
      Alternatively, the scrim  310  is fabricated as an open mesh having woven or nonwoven fiberglass strands. The fiberglass has a higher melt temperature than that of the polyester fibrous composition, which permits the scrim  310  to be added, preferably against the polyurethane layer of the barrier layer  104 , such that the polyester fibrous composition covers the scrim  310 , and further, extends through openings in the scrim  310  to register against the polyurethane layer of the barrier layer  104 . The polyurethane layer of the barrier layer  104  and the scrim  310  thereon are heated at least to the melt temperature of the polyester fibers to melt bond the scrim  310  and the barrier layer  104  to respective polyester fibers.  
      Another embodiment of a bicomponent barrier layer  104  is fabricated by coextrusion of a melt phase polyurethane composition to form a first film layer and a melt phase polyethylene composition to form a second film layer, which film layers are fused together when in melt phase during the coextrusion process, and then solidified by being cooled, to form a composite barrier layer  104  comprised of the two film layers. The polyethylene layer of the barrier layer  104  is substituted for the polypropylene layer in the previously described embodiments of the invention. Further, a fibrous layer  102  or  106  comprised of polyethylene fibers are substituted for the polypropylene fibers in the previously described embodiments of the invention. Except for altering melt temperatures due to substitution of polyethylene for polypropylene, the process of manufacture to form melt bonds is the same by comparison with the previously described embodiments.  
      Preferably, each of the fibrous layers  102  and  106  is chemically compatible with another material  700  and with the thermoplastic composition  108 , respectively, to form a chemical bond, including a melt bond, therewith. For example, the unsaturated polyester fibers are chemically compatible with a polymeric resin including, but not limited to; polyester, polystyrene and polyurethane to form a chemical bond, including a melt bond, therewith. The polypropylene fibers are chemically compatible with a polymeric resin including, but not limited to; polyolefins and polyurethanes to form a chemical bond, including a melt bond, therewith. The polyethylene fibers are chemically compatible with a polymeric resin including, but not limited to, polyolefins to form a chemical bond, including a melt bond, therewith.  
      The preferred fibers of the fibrous layers  102 ,  106  are polyester, polypropylene, polyvinyl chloride or fiberglass, which are chemically compatible with polar (resin swellable) liquid resins comprising, polyester, vinyl ester, styrene, propylene, epoxy and urethane to form a chemical bond, including a melt bond, therewith. Alternatively, polyethylene fibers are chemically compatible with polyethylene liquid resin to form a chemical bond, including a melt bond, therewith.  
      In various embodiments of the invention, the fibrous layer  102 ,  104  has a thiclness in the range of 0.003 inch to 0.100 inch (0.0762 mm. to 2.54 mm.). The thickness of each of the fibrous layers  102 ,  106  is variable for flexibility and size considerations. For example, the thickness comprises a thin, film or veil or tissue. Preferably, a lightweight, flexible composite  2  comprising the barrier layer  104  and the fibrous layers  102 ,  106  has a basis weight of about 100 g/m 2 , and flexible, analogous to a permeable, tissue paper or tissue film. Further, for example, the thickness comprises a permeable mat of greater thickness than a thin, film or veil or tissue. Each of the fibrous layers  102 ,  106  has a basis weight range, 10-200 g/m 2 , for example.  
      Each layer in the bicomponent barrier layer  104  has a single layer thickness in the range of 0.002 inch to 0.005 inch (0.0508 mm. to 0.013 mm.). The scrim  310 , when present has a thickness in the range of 0.004 inch to 0.012 inch (0.0102 mm. to 0.0305 mm.). Preferably each of the fibrous layer  102 ,  106  comprises unwoven fibers, for example, a thermal-bonded carded web, thermal-bonded spun web, chemically-bonded carded web, wet-laid, loose fibers, or a combination thereof. Further, the relative thickness and relative strength, flexibility or stiffniess of the panel  100  depends upon the physical and chemical characteristics of the panel composition  108 , and of the other compositions, which are selected for making the composite  2  prior to assembling the composite  2  on the panel  100 . Further, each layer of the panel  100  and composite  2  is selected to have a composition selection and thickness, which imparts desired mechanical and chemical properties, for example, thinness or thickness, strength or weakness, flexibility or rigidity, resistance to impact or puncture or tear, surface finish, fire resistance, rain and water resistance, ultraviolet radiation resistance, biological fluids resistance and stain resistance.  
      To manufacture planar flat, panels  100 ,  200 ,  300 ,  400  having the cross sections as disclosed by  FIGS. 1-4 , a melt phase polymeric resinous panel composition  108 ,  208 ,  308  or  408  is intended to form a corresponding planar flat, panel with the composite  2 . The panel composition and the composite are applied one on the other. For example, the panel composition  108 ,  208 ,  308  or  408  in a melt phase is spread onto a flat planar forming surface, not shown, on a stationary table or on a moving, continuous conveyor of a known manufacturing apparatus. The corresponding flexible or rigid composite  2  is laid onto the melt phase panel composition  108 ,  208 ,  308  or  408 . Alternatively, the corresponding flexible composite  2  is spread onto a flat planar forming surface, and the melt phase panel composition  108 ,  208 ,  308  or  408  is applied onto the composite  2 . Pressure is applied, for example, against the composite  2  to urge the composite  2  and the melt phase polymeric resinous composition  108 ,  208 ,  308  or  408 , one into the other, causing said composition  108 ,  208 ,  308  or  408  to permeate the corresponding fibrous layer  106 ,  206 ,  306  or  406 , and to permeate the scrim  310  or  410 , when the scrim  310  or  410  is present. The corresponding barrier layer  104 ,  204 ,  304  or  404  is impermeable to the panel composition  108 ,  208 ,  308  or  408  and isolates the corresponding fibrous layer  102 ,  202 ,  302  or  402  from contact by the panel composition. In embodiments wherein the corresponding fibrous layer  106 ,  206 ,  306  or  406  is not present, the corresponding barrier layer  104 ,  204 ,  304  or  404  imbeds at least partially in the melt phase polymeric resinous composition  108 ,  208 ,  308  or  408  and a melt bond is formed therebetween.  
      When the resinous composition  108 ,  208 ,  308  or  408  of the corresponding panel comprises a thermoplastic, the resinous composition  108 ,  208 ,  308  or  408  is rendered to a melt phase, as described herein, for melt bonding the corresponding solid phase barrier layer  104 ,  204 ,  304  or  404  thereto. Alternatively, the surface of the thermoplastic resinous composition  108 ,  208 ,  308  or  408  of the corresponding panel is rendered at least partially to a melt phase state, as described herein, which produces a melt phase surface of the panel composition  108 . Alternatively, when the resinous composition  108 ,  208 ,  308  or  408  of the corresponding panel comprises a thermosetting resinous composition, i.e., a thermoset, the corresponding barrier layer  104 ,  204 ,  304  or  404  melt bonds while said thermosetting resinous composition  108 ,  208 ,  308  or  408  is in a prepolymerized melt phase. Alternatively, the inner surface of the corresponding barrier layer  104 ,  204 ,  304  or  404  is rendered to a melt phase limited to its inner surface by applying surface heat or by applying a thin coating of solvent, which forms a melt phase surface to melt bond with the resinous composition  108 ,  208 ,  308  or  408 .  
       FIG. 5  discloses an embodiment of a method and apparatus for shaping a curvilinear panel  500  and composite  2 . Although  FIG. 5  discloses the flexible composite  2  as comprising the embodiment of  FIG. 1A , alternatively, the flexible composite  2  comprises one of the embodiments of  FIGS. 1A, 2 ,  3  or  4 . The panel  500  and composite  2  are shaped, for example, by molding in a molding apparatus  500   a . The molding apparatus  500   a  has a pair of molding dies  501 ,  502  that close toward each other to define a closed mold cavity  503  therebetween. Although the mold cavity  503  is disclosed by  FIG. 5  as comprising a curvilinear shape, the mold cavity shape comprises alternative embodiments, for example, a flat planar shape that will form a corresponding flat planar panel  100 ,  200 ,  300   400 .  
      The flexible composite  2  for making the panel  500  is placed in the open mold cavity  503 , with the dies  501 ,  502  apart from each other. Then the dies  501 ,  502  are closed. A quantity of a corresponding, permeating resinous panel composition  108 , alternatively,  208 ,  308  or  408 , in a melt phase state is injected into the closed mold cavity  503  to fill the mold cavity  503 , and to permeate a corresponding one of the permeable fibrous layers  106 , alternatively,  206 ,  306  or  406 . Alternatively, the resinous composition  108  is pooled and spread in the mold cavity  503  before the mold dies  501 ,  502  are closed and heat is applied to melt the panel composition  108 .  
      While the dies  501 ,  502  are closed, the corresponding resinous composition  108 , and the composite  2 , are shaped by a corresponding interior shape of the mold cavity  503 . The resinous composition  108  flows under the application of pressure applied by the mold cavity  503 , to fill the mold cavity  503  and bond to the composite  2 . Heat and pressure are applied to promote a low viscosity flow of the melt phase resinous composition  108 . After cooling the resinous composition  108  to form a solidified state, the mold cavity  503  is opened, and the shaped panel  100  and composite  2  are removed. The panel  100  and composite  2  are shaped with one or more, generally curvilinear sections, which conform to the shape of a forming surface  504  of the mold  500   a.    
      With continued reference to  FIG. 5 , the corresponding resinous composition  108  has a corresponding panel surface  107  that is formed against a corresponding forming surface  504  on the mold cavity  503 . The surface texture or smoothness of the forming surface  504  transfers to the panel surface  107 . Alternatively, when the resinous composition  108  has a thickness as disclosed by  FIG. 1B , then the resinous composition  108  will have a corresponding rough surface  107 , due to the presence of the fibrous composition of the fibrous layer  106  near the corresponding surface  107 .  
      In  FIG. 5 , the panel  100  and composite  2  are concave in shape, at least in part. The concave shape is formed against a corresponding forming surface  504  at one side of the mold cavity  503 . Alternatively, the forming surface  504  is concave, instead of convex. A forming surface  504  that is concave can form a convex panel  100  and composite  2 , for example, a convex panel  600  and composite  2 , as disclosed in  FIG. 6 .  
       FIG. 6  discloses an embodiment of a curvilinear, convex panel  600  comprising, for example, a cycler&#39;s helmet. The helmet has a panel  600  that is convex in shape, at least in part, in the form of a shell, for example. The convex shape is formed against a corresponding, forming surface  504  of the mold  500   a  that is concave, instead of being convex as shown in  FIG. 5 . The panel  600  in the mold cavity  503  must be oriented, such that the panel composition  108  of the panel  600  is against the desired forming surface  504 . Alternatively, a curvilinear panel can have both concave and convex portions, by making the forming surface  504  of the mold  500   a  both, convex in part, and concave in part.  
      In each of the embodiments disclosed by  FIGS. 1-6 , preferably, the corresponding fibrous layer  106  is enveloped by a corresponding melt phase, polymeric resinous composition  108 . Further, the corresponding barrier layer  104  is impermeable to the corresponding resinous composition  108 . The resinous composition  108  is against one side of the barrier layer  104 . Advantageously, the corresponding barrier layer  104  separates the resinous composition  108  from a fibrous layer  102  that is against another side of the barrier layer  104 , such that, the fibrous layer  102  is isolated from the resinous panel composition  108 . As disclosed by  FIG. 6 , at least a portion of the fibers in the fibrous layer  102  are at least partially exposed from the barrier layer  104  to adhere another material  700 , to be described.  
      In each of the embodiments disclosed by  FIGS. 1-6 , the barrier layer  104 ,  204 ,  304  or  404  forms an inner boundary of the resinous panel composition  108 ,  208 ,  308  or  408 , which controls the thickness. More specifically, the panel composition  108 ,  208 ,  308  or  408  is applied in a controlled thickness to encase or envelope the fibers of the fibrous layer  106 . For example, a thin, lightweight panel  600  is desired for a cycler&#39;s hehnet, as disclosed by  FIG. 6 . The panel  600  has a panel surface  107  that is smooth, aerodynamic in shape, and resistant to rain, impact and ultraviolet radiation. The absence of a scrim  310  or  410  complements the thinness of the panel  600 .  
      The panel composition  108 ,  208 ,  308  or  408  is applied in a controlled thickness to encase or envelope the fibrous layer  102 ,  202 ,  302  or  402  and the scrim  310  or  410 , when the scrim  310  or  410  is present, as disclosed in  FIGS. 3 and 4 . Alternatively, the panel composition  108 ,  208 ,  308  or  408  is applied in a controlled thickness to have a thickness substantially greater than that of the fibrous layer  106 ,  206 ,  306  or  406 , as disclosed in  FIGS. 2, 4 ,  8  and  9 .  
      In  FIGS. 1-6 , individual fibrous layers  102 ,  106 ,  202 ,  206 ,  302 ,  306 ,  402  or  406  are thin to comprise a thin veil or tissue, in which lengths of individual fibers are nonwoven and lay substantially elongated within and along the thickness plane of the veil or tissue. In an alternative embodiment, the individual fibers are larger in diameter, or larger in cross section, to form a correspondingly thicker fibrous layer. In another alternative embodiment, the individual fibers are overlapped or stacked, one on another, or are interwoven to build up the number of fibers that cumulatively contribute to the thickness. In another alternative embodiment the ends of the individual fibers project or point themselves in outward directions to provide a raised nap that increases the thickness.  
      For example, each of the two permeable fibrous layers  102 ,  106 ,  202 ,  206 ,  302 ,  306 ,  402  or  406  of fibrous composition is preferably 3-20 thousandths inch thick. The barrier layer  104  is preferably 1-5 thousandths inch thick. The scrim  310  or  410  is preferably 4-12 thousandths inch thick. Thus, by selecting a relatively thin barrier layer  104 ,  204 ,  304  or  404  and two relatively thin permeable fibrous layers  102 ,  106 ,  202 ,  206 ,  302 ,  306 ,  402  or  406 , a relatively thin panel  100  is fabricated. The embodiments according to  FIG. 3  or  FIG. 4  may be fabricated when additional reinforcement is provided by having the scrim  310 ,  410  present in the corresponding fibrous layer, for embedding in the corresponding panel composition  308 ,  408 .  
      According to each of  FIGS. 1, 5  and  6 , the flexible composite  2  is formed by at least two flexible, fibrous layers  102 ,  106  bonded to opposite sides of a flexible, barrier layer  104 . According to embodiments disclosed by  FIGS. 3 and 4 , the corresponding flexible scrim  310  or  410  is bonded to a side of a corresponding barrier layer  304  or  404 . The composite  2  is bendable or flexible to follow the course of an exemplary bent or curvilinear path, embodiments of which are disclosed in  FIGS. 5 and 6 .  
      Each of  FIGS. 7, 8 ,  9  and  10  discloses a corresponding embodiment of the invention, in which the fibrous layer  102  thereof, is isolated by the barrier layer  104  to be free of the permeating panel composition  108 . At least portions of the fibers in the fibrous layer  102  thereof, are at least partially exposed from the barrier layer  104  to adhere another material  700 . Further, adherence is enhanced by optional swelling of the fibrous layer  102  thereof, within said another material  700 .  
      In the embodiment disclosed by  FIG. 7 , the fibrous layer  102  of the panel  100  is permeated by said another material  700  comprising an adhesive to adhere a tangible object  702  including, but not limited to, a layer of soft material for a cushion or pad to line the cycler&#39;s helmet  600  disclosed in  FIG. 6 . Further, alternatively, the panel  100  comprises a shell for a contoured chair or other seating formed, for example, by a molding process according to  FIG. 5 . The tangible object  702  for the chair or other seating comprises a cushion for the chair or other seating instead of for a helmet  600 . In another embodiment disclosed by  FIG. 7 , for example, said another material  700  comprises an adhesive adhering to a tangible object  702  comprising another panel in the form of a stationary wall, a partition, flooring, a ceiling, a shaped vessel hull or a shaped wall of a container, such as, a refrigerator. Alternatively, the panel  100  comprises a liner for lining a tangible object  702  including, but not limited to, a bathtub or a shower stall. Further, alternatively, the panel  100  comprises part of a shaped panel  702  formed into a contoured chair or other seating. For example, said another material  700  is formed in situ in a melted, melt phase or fluent state, to permeate the fibrous layer  102  thereof.  
      Further, for example, the other material  700  includes, but is not limited to, a polymeric resin composition of polyurethane, polystyrene or polyamide, with a foaming agent that permeates the fibrous layer  102  thereof. An embodiment of said other material  700  of sufficient thickness comprises a thickened cushion or padding, for example, which is ideal for cushioning a cycler&#39;s helmet  600 , as disclosed by  FIG. 6 , or for cushioning a chair or other seating. Alternatively, the other material  700  comprises, a thermally insulated, or sound insulated, exterior panel  100  for covering said tangible object  702 , wherein said tangible object  702  comprises a wall, a partition, a ceiling or a floor. Further, an alternative embodiment of the panel  100  is insulated by the other material  700  to comprise an insulated interior panel  100  for lining the interior of a large or small container or vessel, including, but not limited to, the interior of a refrigerator or the interior of a thermally insulated or sound insulated carrel or stall.  
      Advantageously, the panel  100  is assembled with the composite  2 , such that the panel  100  is provided with the fibrous layer  102  to adhere another material  700 . Further, such material  700  includes, but is not limited to, a thermoset or thermoplastic resinous composition or other organic composition. Examples include, but are not limited to, unsaturated polyester, vinyl ester, epoxy, Novolac epoxy and high temperature epoxy and variants, urea formaldehyde, phenol formaldehyde, orthophthalate polyester, isophthalate polyester, acrylic, and methacrylic. Further variants of the material  700  comprise air entrained or foamed compositions, compositions reinforced with fibers, compositions treated with one or more active reagents or non-reactive agents serving as, a filler, colorant, fire retardant, biocide, or fluid repellant.  
      According to further embodiments of the invention, as disclosed by  FIG. 9 , said another material  700  comprises a thermal insulation, a sound absorbent composition, a cushion, padding or a filler, which is formed in situ to permeate the fibrous layer  102  thereof, that is isolated by the barrier layer  104  to be free of the panel composition  108 .  
      Further, with reference to  FIG. 8 , in an alternative embodiment, the panel  100  is reinforced by adding the scrim  310  to the composite  2 .  
       FIG. 9  discloses an embodiment of the panel  100 , which is similar to the embodiment disclosed by  FIG. 8 . Further,  FIG. 9  discloses an embodiment of a panel  100 , wherein the other material  700  is formed in situ between the fibrous layer  102  and a tangible object  702  comprising a fixed wall or another panel, which can comprise, for example, an interior or exterior building wall or panel, a partition wall, a container wall or a vessel wall, including, but not limited to, the wall of a refrigerator or the wall of a thermally insulated or sound insulated carrel or stall. The other material  700  adheres to the wall or panel  702 , as well as, melt bonds to the barrier layer  104  and the fibrous layer  102  thereof. Further,  FIG. 9  discloses the other material  700  permeating a reinforcement scrim  310  that is added to the composite  2 , and which reinforces the other material  700 . According to an embodiment, the reinforcement scrim  310  is absent from the composite  2 . According to another embodiment, a reinforcement scrim  310  or  410  is present, as disclosed by  FIGS. 3 and 4 .  
       FIG. 10  discloses an embodiment of the panel  100  that is similar to the embodiment disclosed by  FIG. 102 . Further,  FIG. 10  discloses, an adhesive panel composition  108  on a surface of, a wall, ceiling, floor or roadway, followed by applying the fibrous layer  106  of the panel  100  onto the adhesive panel composition  108 , causing the panel composition  108  to permeate the fibrous layer  106 . The fibrous composition of the fibrous layer  106  provides a non-skid surface  107  against the corresponding wall, ceiling, floor or roadway. Further,  FIG. 10  discloses the other fibrous layer  102  thereof, that is free of the permeating composition of the panel composition  108 , for attaching to further compositions that would cover and permeate the fibrous layer  102  thereof to form a panel  104 , wherein the panel  104  includes, but is not limited to; wall paneling, cementitious paneling, ceiling paneling, flooring or a panel of bituminous road surfacing composition.  
      Additional compositions for manufacturing each fibrous layer  102 , the barrier layer  104  and the scrim  310  are disclosed in U.S. Ser. No. 10/843,257, filed May 11, 2004, published application US 2004/0214489 A1, and in U.S. Ser. No. 10/731,767, filed Dec. 9, 2003, published application US 2005/0124240.  
      Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention. Pending patent applications and publications referred to hereinabove are expressly incorporated herein by reference.