Abstract: A coated tow includes a fiber bundle composed of continuous reinforcement fibers that form a flat substrate in a ribbon shape and a thermoplastic-based overcoating applied to the flat substrate to form a uni-directional tape. An extruded tape includes a plurality of cords of twisted fiber yarns each composed of continuous reinforcement fibers, a thermoplastic overcoating applied to each of the cords, and a high density polyethylene (HDPE) that encases the plurality of cords to form a uni-directional tape. The reinforcement fibers have continuous filaments aligned lengthwise along a length each of the cords. A process of producing the coated tow or extruded tape includes feeding one or more spools of continuous fiber tow under tension control, sinking the continuous fiber tow in a chemical bath, passing the wetted continuous fiber tow through one or more squeezing rollers, and passing the continuous fiber tow through an oven.

Abstract: A fiber preform for use in an overmolding process is provide that includes a fiber bundle arranged in a predetermined pattern and attached to itself with thread stitches to form at least one preform layer. At least one intumescent material is associated with the at least one preform layer. A vehicle component having fire resistant characteristics is also provided that includes a housing having a first side and a second side. The housing has a shape that defines the vehicle component. An intumescent material is provided on at least one of the first side and the second side of the housing.

Abstract: Flame resistant fabrics are provided that exhibit improved protection from molten metal spills, metal splatter, electric arc, and related thermal hazards illustratively including open flame and radiant heat. The flame resistant fabrics are made from a combination of cellulosic fibers and thermoplastic fibers, where the flame resistant fabric forms a char layer that does not become brittle when contacted by molten metal, metal splatter, electric arc, and related thermal hazards. By not becoming brittle the likelihood of break out of the fabric is minimized, thereby improving the level of protection to the user. As a result, the flame resistant fabric retains the desirable properties of fibers formed of organic materials in terms of comfort, weight, and durability.

Abstract: A process for forming a nonwoven composite begins with forming a first nonwoven from a plurality of primary fibers and optionally binder fibers. A second nonwoven layer is formed from a plurality of bulking fibers and binder fibers. A thermoplastic elastomeric film is placed between the two nonwoven layers, the film containing a thermoplastic elastomeric polymer having an elongation at break greater than 300% and a max softening point (thermomechanical analysis end point) between 150° C. and 200° C. as tested according to ASTM E2347-04. The layers are needled together creating a plurality of holes in the thermoplastic elastomeric layer and moving a portion of the primary fibers from the first nonwoven layer into the second nonwoven layer. The needled stacked layers are heated to alter the median size of the holes in the thermoplastic elastomeric film forming the nonwoven composite.

Abstract: A process for forming a moldable, uncured nonwoven composite containing forming a outermost nonwoven layer, forming a structural nonwoven layer, needling the structural nonwoven layer and the outermost nonwoven layer together from both the outer surface of the outermost nonwoven layer and the second surface of the structural nonwoven layer, applying an uncured, water-based thermosetting resin having a cure temperature of at least about 160° C. to the second surface of the structural nonwoven layer, and at least partially drying the uncured, wet nonwoven composite. Heat and pressure may be applied to form the moldable, uncured composite. A moldable, uncured nonwoven composite and a molded, cured nonwoven composite are also disclosed.

Abstract: A process for forming a moldable, uncured nonwoven composite containing forming a structural nonwoven layer, at least partially impregnating the structural nonwoven layer with an uncured, water-based thermosetting resin having a cure temperature of at least about 160° C., and at least partially drying the uncured, wet nonwoven composite such that the temperature at the inner plane is less than about 130° C. forming an moldable, uncured composite. The structural nonwoven layer contains a plurality of bi-component binder fibers and a plurality of reinforcing fibers, the bi-component fibers containing a core and a sheath. The core contains a polymer having a melting temperature of at least about 180° C. and the sheath contains a polymer having a melting temperature less than about 180 ° C. A process for forming a molded, cured composite containing forming a structural nonwoven layer and a molded cured nonwoven composite are also disclosed.

Abstract: A nonwoven composite containing a first nonwoven layer having a plurality of primary fibers and optionally binder fibers, a thermoplastic film comprising a thermoplastic polymer having an elongation at break greater than 300% and a max softening point (thermomechanical analysis end point) between 150° C. and 200° C. as tested according to ASTM E2347-04 and containing a plurality of holes and an air flow resistance great than 1,500 Rayls. A second nonwoven layer having a plurality of bulking fibers and optionally binder fibers. The thermoplastic film is adjacent the bottom surface of the first nonwoven layer and the top surface of the second nonwoven layer and sandwiched between the first and second nonwoven layers. At least a portion of the primary fibers from the first nonwoven layer are located in the holes of the thermoplastic film and within the second nonwoven layer.

Abstract: A nonwoven composite containing a first nonwoven layer having a plurality of primary fibers and optionally binder fibers, a thermoplastic film comprising a thermoplastic polymer having an elongation at break greater than 300% and a max softening point (thermomechanical analysis end point) between 150° C. and 200° C. as tested according to ASTM E2347-04 and containing a plurality of holes and an air flow resistance great than 1,500 Rayls. A second nonwoven layer having a plurality of bulking fibers and optionally binder fibers. The thermoplastic film is adjacent the bottom surface of the first nonwoven layer and the top surface of the second nonwoven layer and sandwiched between the first and second nonwoven layers. At least a portion of the primary fibers from the first nonwoven layer are located in the holes of the thermoplastic film and within the second nonwoven layer.

Abstract: A process for forming a nonwoven composite begins with forming a first nonwoven from a plurality of primary fibers and optionally binder fibers. A second nonwoven layer is formed from a plurality of bulking fibers and binder fibers. A thermoplastic elastomeric film is placed between the two nonwoven layers, the film containing a thermoplastic elastomeric polymer having an elongation at break greater than 300% and a max softening point (thermomechanical analysis end point) between 150° C. and 200° C. as tested according to ASTM E2347-04. The layers are needled together creating a plurality of holes in the thermoplastic elastomeric layer and moving a portion of the primary fibers from the first nonwoven layer into the second nonwoven layer. The needled stacked layers are heated to alter the median size of the holes in the thermoplastic elastomeric film forming the nonwoven composite.

Abstract: A process for forming a moldable, uncured nonwoven composite containing forming a structural nonwoven layer, at least partially impregnating the structural nonwoven layer with an uncured, water-based thermosetting resin having a cure temperature of at least about 160° C., and at least partially drying the uncured, wet nonwoven composite such that the temperature at the inner plane is less than about 130° C. forming an moldable, uncured composite. The structural nonwoven layer contains a plurality of bi-component binder fibers and a plurality of reinforcing fibers, the bi-component fibers containing a core and a sheath. The core contains a polymer having a melting temperature of at least about 180° C. and the sheath contains a polymer having a melting temperature less than about 180 ° C. A process for forming a molded, cured composite containing forming a structural nonwoven layer and a molded cured nonwoven composite are also disclosed.

Abstract: A process for forming a moldable, uncured nonwoven composite containing forming a outermost nonwoven layer, forming a structural nonwoven layer, needling the structural nonwoven layer and the outermost nonwoven layer together from both the outer surface of the outermost nonwoven layer and the second surface of the structural nonwoven layer, applying an uncured, water-based thermosetting resin having a cure temperature of at least about 160° C. to the second surface of the structural nonwoven layer, and at least partially drying the uncured, wet nonwoven composite. Heat and pressure may be applied to form the moldable, uncured composite. A moldable, uncured nonwoven composite and a molded, cured nonwoven composite are also disclosed.

Abstract: A process for forming a moldable, uncured nonwoven composite containing forming a structural nonwoven layer, at least partially impregnating the structural nonwoven layer with an uncured, water-based thermosetting resin having a cure temperature of at least about 160° C., and at least partially drying the uncured, wet nonwoven composite. The structural nonwoven layer contains a plurality of binder fibers and a plurality of reinforcing fibers which are cellulosic fibers. Heat and pressure are applied to the moldable, uncured composite to a temperature of at least about 160° C. at least partially melting the binder fibers, curing the water-based thermosetting resin, and bonding at least a portion of the reinforcing fibers to other reinforcing fibers forming the molded, cured composite. The reinforcing fibers react with and form covalent bonds with the thermosetting resin.

Abstract: Disclosed is a method of strengthening existing structures containing the following steps. An existing structure made of concrete, steel, timber, masonry to be reinforced and a reinforcing sheet are provided, where the reinforcing sheet contains an alternating arrangement of reinforcement zones and slitting zones. The reinforcement zones contain unidirectional strengthening fibers in the warp direction of the reinforcement sheet and the slitting zones have an absence of strengthening fibers. The reinforcement sheet is slit through the slitting zones and the reinforcement zones are adhered to the existing structure.

Abstract: A needled, non-woven having a first zone extending from an upper surface to an inner plane and a second zone extending from the inner plane to a lower surface. The first zone comprises a plurality of first core/sheath fibers, a plurality of second fibers, and a plurality of third fibers, The second polymer forming the second fibers and the sheath polymer forming the sheath of the first core/sheath fibers have a critical surface energy less than 40 mN/m. The second zone comprises a plurality of fourth fibers and a plurality of fifth fibers. A portion of the first core/sheath fibers, second fibers, and third fibers from the first zone are physically entangled into the fourth fibers and fifth fibers in the second zone. A consolidated needled non-woven and method for making the needled non-woven and consolidated needled non-woven are also disclosed.

Abstract: An improved, composite textile that can become rigid or semi-rigid by e.g., applying a liquid is provided. The composite can include a high loft non-woven layer having a first face and a second face and a midpoint between the first face and the second face. The high loft non-woven layer includes bulking fibers crossing the midpoint plane that form a tangential line at the midpoint plane that is at non-zero angle as set forth herein.

Abstract: Disclosed is a method of strengthening existing structures containing the following steps. An existing structure made of concrete, steel, timber, masonry to be reinforced and a reinforcing sheet are provided, where the reinforcing sheet contains an alternating arrangement of reinforcement zones and slitting zones. The reinforcement zones contain unidirectional strengthening fibers in the warp direction of the reinforcement sheet and the slitting zones have an absence of strengthening fibers. The reinforcement sheet is slit through the slitting zones and the reinforcement zones are adhered to the existing structure.

Abstract: An improved, composite textile that can become rigid or semi-rigid by e.g., applying a liquid is provided. The composite can include a high loft non-woven layer having bulking fibers and a binding material; a cured rigid or semi-rigid solid located in the high loft non-woven; a filter layer on a first face of the high loft non-woven layer; and a liquid barrier layer on a second face of the high loft non-woven layer. The liquid barrier layer may have a difference in in-plane stiffness as set forth herein. The distance between the first face and second face of the high loft non-woven layer may not vary by more than a certain localized distance across the high loft non-woven layer when the high loft non-woven layer is in a flat state or has a radius of curvature of not less than the thickness of the non-woven layer as set forth herein.

Abstract: A process for forming a high efficiency filter containing the steps of forming a non-woven layer having pores from a plurality thermoplastic fibers having a median diameter of less than about 2 micrometers, saturating the non-woven layer in a wetting liquid, and drying the wetted non-woven layer.

Abstract: Disclosed is a method of strengthening existing structures containing the following steps. An existing structure made of concrete, steel, timber, masonry to be reinforced and a reinforcing sheet are provided, where the reinforcing sheet contains an alternating arrangement of reinforcement zones and slitting zones. The reinforcement zones contain unidirectional strengthening fibers in the warp direction of the reinforcement sheet and the slitting zones have an absence of strengthening fibers. The reinforcement sheet is slit through the slitting zones and the reinforcement zones are adhered to the existing structure.

Abstract: A flexible textile or cloth is provided that can be hardened to a rigid or semi-rigid condition. The textile can incorporate reinforcement fibers to provide improved mechanical properties. The reinforcement fibers can be added in a various configurations without unnecessarily increasing the weight of the textile. Further, the textile can include at least one flap to facilitate readily joining the textile with another component such as another textile to create a composite construction.