Abstract: A method for manufacturing a plastic composite uses recycled thermoplastic material comprising the steps of (1) providing flakes of thermoplastic materials to be recycled; (2) mixing the thermoplastic flakes, thereby forming a thermoplastic matrix having a first melting temperature; (3) forming or providing a web-structure of a predetermined thickness from fibers having a second melting temperature higher than the first melting temperature; (4) evenly distributing the thermoplastic matrix of thermoplastic flakes over the web-structure; (5) optionally forming or providing a second web-structure and placing it over the thermoplastic matrix; (6) optionally repeating steps (4) and (5); and (7) heating the web at a temperature between the first and second temperature using a thermoforming process.

Abstract: A composite board is at least partially made of a nonwoven composite material. The nonwoven composite material includes bast fibers and/or glass fibers, plastic fibers, and between 10 and 75% weight of cured liquid based thermoset. Further, such composite board is used in all applications wherein Particle Board (PB), Medium and High Density Fibreboard (MDF & HDF), Oriented Strand Board (OSB), Laminated Veneer Lumber (LVL), Plywood (PLW), and related materials are used, and in wall panels, separation panels, insulation panels, laminates, flooring, in particular laminate flooring, tiles, furniture, and related applications. In addition, a process for manufacturing a composite board includes mixing bast fibers and/or glass fibers with plastic fibers, thereby forming a fiber layer, and thermoforming the fiber layer into a nonwoven composite material layer. The thermoforming includes impregnating the fiber layer under vacuum conditions with liquid thermoset and heating.

Abstract: A load carrier is at least partially made of a nonwoven composite material board. The nonwoven composite material board comprising: includes unraveled natural fibers and/or glass fibers, and plastic fibers. Also disclosed is a process for manufacturing a load carrier. The process includes mixing unraveled natural fibers and/or glass fibers, and plastic fibers, and thermoforming the mix into a nonwoven composite material layer. The disclosed load carriers may be any type of load carriers, such as boxes, top decks, cases, crates, and the like, and in particular, pallets.

Abstract: A composite board is made at least partially of a nonwoven composite material. The nonwoven composite material includes unraveled natural fibers and/or glass fibers, plastic fibers, and between 0 and 50% weight of thermoharder. Also, a process for manufacturing the composite board comprises mixing unraveled natural fibers and/or glass fibers with plastic fibers, and with less than 50% weight thermoharder, and thermoforming the mix into a nonwoven composite material layer. Further, the composite board is for use in all applications wherein Particle Board, Medium and High Density Fibreboard, Oriented Strand Board, Laminated Veneer Lumber, Plywood and related materials are used, and in wall panels, separation panels, insulation panels, laminates, flooring, in particular laminate flooring, tiles, furniture, and related applications.

Abstract: The invention relates to a process and composition for binding of a particulate or fibrous substrate, in particular natural particles or fibres such as for example wood particles and fibers, but also other natural fibers such as straw, flax, grass, straw, hemp, bagasse and bamboo. The current invention describes the composition of a cheap binder that can bind particles and fibers in a fast way, resulting in substrates that have the required mechanical properties. The binder has a good sustainability so that the end product also has an improved sustainability profile. Furthermore, the new binder composition will make the resulting substrates (composite materials) flame retardant.