Abstract: A primary homo staple fiber including a melt-modified polyester component having a melt temperature in the range of 100 degrees Celsius to 260 degrees Celsius and configured in staple fiber form. Also, a non-woven composite article including a primary homo staple fiber including a melt-modified polyester component configured in staple fiber form and having melt temperature in the range of 100 degrees Celsius to 260 degrees Celsius. Also, a non-woven composite article including a non-woven composite material, the non-woven composite material including a fibrous first component of singular fibers of melt-modified polyester configured in a staple fiber form, and a fibrous second component including one or more fibers of various type, the fibrous first and second components are blended together, and the melt-modified polyester includes a low melting point polyethylene terephthalate (LPET) polyester as a primary binder in the non-woven composite material.

Abstract: Non-woven matrices and, more particularly, cotton shoddy and/or natural fiber matrices, and systems and methods for producing the matrices are described herein.

Abstract: A fire retardant structural board is provided that includes a body of fibrous material, a triglycidyle polyester binder, a sodium borate pentahydride fire retardant, and a sodium borate pentahydride fire retardant. The body of fibrous material has a weight, first and second surfaces, first and second sides, and a thickness. The fibrous material and triglycidyle polyester are dispersed throughout the thickness of the body. The sodium borate pentahydride fire retardant is dispersed between individual fibers of the fibrous material and throughout the thickness of the body. A sodium borate pentahydride fire retardant composition also coats at least the first surface of the body.

Abstract: A blow-molded composite and method of making the same is provided. The composite includes first and second fibrous layers and first and second film layers. The first fibrous layer includes randomly oriented fibers dispersed throughout the thickness of the layer and has first and second surfaces. The first film layer has first and second surfaces such that the second surface of this layer is bonded to the second surface of the first fibrous layer. The second film layer has first and second surfaces as well, but only a portion of the first surface is bonded to the first surface of the first film layer. At least one cavity exists between the first and second film layers. The second fibrous layer also comprises randomly oriented fibers dispersed throughout the thickness of the layer and has first and second surfaces. The first surface of the second fibrous layer is bonded to the second surface of the second film layer.

Abstract: A fire retardant structural board is provided that includes a body of fibrous material, a triglycidyle polyester binder, a sodium borate pentahydride fire retardant, and a sodium borate pentahydride fire retardant. The body of fibrous material has a weight, first and second surfaces, first and second sides, and a thickness. The fibrous material and triglycidyle polyester are dispersed throughout the thickness of the body. The sodium borate pentahydride fire retardant is dispersed between individual fibers of the fibrous material and throughout the thickness of the body. A sodium borate pentahydride fire retardant composition also coats at least the first surface of the body.

Abstract: The following disclosure provides a structural mat for manufacturing a moldable structural hardboard body. The structural mat has a nucleated/coupled binder and a fibrous material. The nucleated/coupled binder material has a first binder material combined with a nucleating agent; and a second binder material combined with a coupling agent. The first binder material is combined with the nucleating agent to make a discrete nucleated/binder material. The second binder material is combined with the coupling agent to make a discrete coupled/binder material. The discrete nucleated/binder material and the discrete coupled/binder material are blended together. The fibrous material is blended with the discrete nucleated/binder material and the discrete coupled/binder material to form the structural mat.

Abstract: A fire retardant structural board is provided that includes a body of fibrous material, a triglycidyle polyester binder, a sodium borate pentahydride fire retardant, and a sodium borate pentahydride fire retardant. The body of fibrous material has a weight, first and second surfaces, first and second sides, and a thickness. The fibrous material and triglycidyle polyester are dispersed throughout the thickness of the body. The sodium borate pentahydride fire retardant is dispersed between individual fibers of the fibrous material and throughout the thickness of the body. A sodium borate pentahydride fire retardant composition also coats at least the first surface of the body.

Abstract: A fire retardant structural board is provided that includes a body of fibrous material, a triglycidyle polyester binder, a sodium borate pentahydride fire retardant, and a sodium borate pentahydride fire retardant. The body of fibrous material has a weight, first and second surfaces, first and second sides, and a thickness. The fibrous material and triglycidyle polyester are dispersed throughout the thickness of the body. The sodium borate pentahydride fire retardant is dispersed between individual fibers of the fibrous material and throughout the thickness of the body. A sodium borate pentahydride fire retardant composition also coats at least the first surface of the body.

Abstract: A laminated composite material is provided. The material has first and second layers. The first layer is composed of a fibrous material and a binder, and the second layer is composed of a woven material and a binder.

Abstract: The following disclosure provides a low-density fire retardant structural board. The board has a body of fibrous material, a binder and fire retardant agent. The body of fibrous material includes a weight, first and second ends, first and second sides and a thickness. The fibrous material is dispersed throughout the thickness of the body. The binder is also dispersed throughout the thickness of the body. The fire retardant agent is dispersed between individual fibers of the fibrous material and throughout the thickness of the body.

Abstract: A fire retardant structural board is provided that includes a body of natural fibrous material, a triglycidyle polyester binder, a sodium borate pentahydride fire retardant, and a sodium borate pentahydride fire retardant. The body of natural fibrous material has a weight, first and second surfaces, first and second sides, and a thickness. The natural fibrous material and triglycidyle polyester are dispersed throughout the thickness of the body. The sodium borate pentahydride fire retardant is dispersed between individual natural fibers of the natural fibrous material and throughout the thickness of the body. A sodium borate pentahydride fire retardant composition also coats at least the first surface of the body.

Abstract: A reinforcing core structure for a composite panel includes a body having a plurality of generally parallel, alternating ridges and grooves, in which walls extending between the ridges and grooves have a corrugated surface. The resulting core structure has an open honeycomb geometry that may be employed in various applications to provide a composite panel exhibiting an exceptional strength to weight ratio. In accordance with certain preferred embodiments, the panels may comprise reinforcing core structures fabricated from fibrous bodies containing a binder material to provide inexpensive structural members exhibiting excellent mechanical properties.

Abstract: An improved process for more economically and efficiently making a fibrous article optionally including one or more functional components includes steps of providing a fibrous body comprising natural fibers, synthetic fibers, glass fibers or a combination of these fibers; generating a foam comprising a continuous liquid phase and a dispersed gaseous phase; and impregnating the fibrous body with the foam by applying the foam to at least one surface of the fibrous body.

Abstract: A panel is provided having a surface layer. The surface layer includes a surface that is the exterior surface of the panel. The surface layer includes a blend of nucleated binder fibers and synthetic fibers and forms a finishable, substantially defect and porosity free surface layer based on visual inspection.

Abstract: A vehicle headliner panel is provided which has a core layer having a binding resin, randomly-oriented sisal fibers, and randomly-oriented natural filler fibers.

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.

Abstract: A laminated composite material is provided. The material has first and second layers. The first layer is composed of a fibrous material and a binder, and the second layer is composed of a woven material and a binder.