Patent ID: 7918952

Claim:
A process of transforming ground headliner into a rigid and solid usable substance; comprising the steps of: a) making a thermal binder by: i) blending a first combination of polyester/polyethylene fibers with a specific gravity of from about 0.91 g/cm 3 to about 0.97 g/cm 3 and melting points from about 175° C. to about 250° C. such that said first combination constitutes from about 30% w/w to about 70% w/w of said thermal binder; and ii) blending a second combination of polypropylene/polyethylene fibers with a specific gravity of from about 0.92 g/cm 3 to about 0.94 g/cm 3 and melting points from about 175° C. to about 250° C. such that said second combination constitutes from about 30% w/w to about 70% w/w of said thermal binder; b) using a forced-air mixer to mix said thermal binder and said ground headliner to create a bondable mixture; and c) applying heat to said bondable mixture to melt said thermal binder; and allowing said bondable mixture to cool, thereby creating said rigid solid usable substance.