Abstract: Cast-film process for making a fiber-reinforced film is disclosed. The process includes providing at least a first thermoplastic resin, melting the at least first thermoplastic resin, extruding the at least first thermoplastic resin through a first extension die to form a first thermoplastic film, providing at least a second thermoplastic resin, melting the at least second thermoplastic resin, extruding the at least second thermoplastic resin through a second extension die to form a second thermoplastic film, transporting the first and second thermoplastic films along respective casting rollers, and introducing a plurality of fibers between the first and second thermoplastic films so as to form a fiber-reinforced film having a thickness between about 0.2 mil to about 2.0 mils and having a first thermoplastic layer, a second thermoplastic layer, and a plurality of fibers dispersed therebetween. Cast-film process for making a fiber-reinforced bag is also disclosed.

Abstract: Hydroculture media can be a synthetic soil including a three dimensional solid made of a plurality of fibers. The three dimensional solids can be a variety of shapes, such as spheres, cylinders, cones, cubes, cuboids, parallelepipeds, polyhedrons (e.g., pyramid, tetrahedron, octahedron, dodecahedron, icosahedron), prisms, spheroids, ellipsoids, paraboloids, hyperboloids, rings, and combinations thereof. The solids can have a length/diameter ratio in the range of 0.1-5:1. Some or all of the fibers can include an antimicrobial substance and/or plant nutrients.

Abstract: An interior component for a vehicle may include a nonwoven fabric impregnated with a resin. The nonwoven fabric and resin are consolidated into a solid sheet devoid of pockets. The interior component may exclude metal coated filler particles and lubricants. The method of making the interior component includes the steps of: forming a nonwoven fabric of a staple fiber and a resin, consolidating the nonwoven fabric and the resin into a solid sheet, and forming the solid sheet into the vehicle component. The vehicle may be an airplane, train, subway car, light rail car, bus, or automobile. The resin may be a polymer selected from the group consisting of polyphenylene sulfide, polyetherimide, polyaryletherketone, co-polymers thereof, and combinations thereof.

Abstract: A heat shield is generally provided, along with methods of making the heat shield and its use in a vehicle safety device (e.g., an airbag). In one embodiment, the heat shield includes a base substrate (e.g., a nonwoven fabric, a woven fabric, or a film); a heat resistant coating on the base substrate; and a first point-bonded sheet laminated to the heat resistant coating such that the first point-bonded sheet forms an outer surface of the heat shield with the heat resistant coating positioned between the first point-bonded sheet and the base substrate. The heat resistant coating generally comprises particles of an inorganic mineral (e.g., vermiculite, mica, or a combination thereof) dispersed within a film-forming binder (e.g., an acrylic resin, a styrene-butadiene rubber, a polyvinyl alcohol, an ethyl vinyl acetate resin, a phenolic resin, or a combination thereof).

Abstract: A filter medium for removing oil from an aqueous material can include a three dimensional solid made from a plurality of fibers, in which at least some of the fibers are oleophilic or oleophilic and hydrophilic. The solid can be a variety of shapes, such as a sphere, cylinder, cone, cube, cuboid, parallelepiped, polyhedron, prism, spheroid, ellipsoid, paraboloid, hyperboloid, ring and/or combinations thereof.

Abstract: A compressible filter media can be formed from discrete fibrous elements adapted for receiving a fluid therethrough and filtering matter contained within the fluid. Each of the fibrous elements can be a three dimensional shape, such as a sphere, cylinder, cone, cube, cuboid, parallelepiped, polyhedron, prism, spheroid, ellipsoid, paraboloid, hyperboloid, and ring.

Abstract: A blown-film process for making a fiber-reinforced film comprises providing and melting at least one thermoplastic resin. The at least one thermoplastic resin is extruded through an extension die to form a film bubble. A plurality of fibers is introduced inside of the film bubble. The fibers are distributed inside of the film bubble. The film bubble is collapsed after introducing the plurality of fibers so as to form a fiber-reinforced film. The fiber-reinforced film has a first thermoplastic layer, a second thermoplastic layer, and a plurality of fibers dispersed therebetween. The film may be formed in a bag.

Abstract: A heat shield is generally provided, along with methods of making the heat shield and its use in a vehicle safety device (e.g., an airbag). In one embodiment, the heat shield includes a base substrate (e.g., a nonwoven fabric, a woven fabric, or a film); a heat resistant coating on the base substrate; and a first point-bonded sheet laminated to the heat resistant coating such that the first point-bonded sheet forms an outer surface of the heat shield with the heat resistant coating positioned between the first point-bonded sheet and the base substrate. The heat resistant coating generally comprises particles of an inorganic mineral (e.g., vermiculite, mica, or a combination thereof) dispersed within a film-forming binder (e.g., an acrylic resin, a styrene-butadiene rubber, a polyvinyl alcohol, an ethyl vinyl acetate resin, a phenolic resin, or a combination thereof).

Abstract: An interior component for a vehicle may include a nonwoven fabric impregnated with a resin. The nonwoven fabric and resin are consolidated into a solid sheet devoid of pockets. The interior component may exclude metal coated filler particles and lubricants. The method of making the interior component includes the steps of: forming a nonwoven fabric of a staple fiber and a resin, consolidating the nonwoven fabric and the resin into a solid sheet, and forming the solid sheet into the vehicle component. The vehicle may be an airplane, train, subway car, light rail car, bus, or automobile. The resin may be a polymer selected from the group consisting of polyphenylene sulfide, polyetherimide, polyaryletherketone, co-polymers thereof, and combinations thereof.

Abstract: A blown-film process for making a fiber-reinforced film comprises providing and melting at least one thermoplastic resin. The at least one thermoplastic resin is extruded through an extension die to form a film bubble. A plurality of fibers is introduced inside of the film bubble. The fibers are distributed inside of the film bubble. The film bubble is collapsed after introducing the plurality of fibers so as to form a fiber-reinforced film. The fiber-reinforced film has a first thermoplastic layer, a second thermoplastic layer, and a plurality of fibers dispersed therebetween. The film may be formed in a bag.

Abstract: An acoustically insulating product for acoustically insulating a building structure includes a base entangled net material, and an acoustical nonwoven material. The acoustical nonwoven material is on at least one side of the base entangled net material. The acoustical nonwoven material has an increase in impact insulation class of 6 or greater.

Abstract: A material and method for insulating and providing a drainage path for a foundation wall includes a non-woven thermoplastic board being for insulating and providing a drainage path for a foundation wall. The non-woven thermoplastic board has a thermal resistance of an R-value per inch thickness of at least 1. The non-woven thermoplastic board also has a vertical drainage ability per inch thickness of at least 135 Gallons/Hour/Lineal-Foot/inch at a pressure of 500 pounds per square foot (psf).

Abstract: A water vapor barrier material for a building structure includes a base entangled net material and a composite nonwoven. The composite nonwoven includes a film layer with a nonwoven layer on each side of the film layer. The film layer has a water vapor transmission rate of less than 10.0 g-MIL/100-in2/day at a temperature of 100 degrees Fahrenheit and 90 percent relative humidity.

Abstract: A blown-film process for making a fiber-reinforced film comprises providing and melting at least one thermoplastic resin. The at least one thermoplastic resin is extruded through an extension die to form a film bubble. A plurality of fibers is introduced inside of the film bubble. The fibers are distributed inside of the film bubble. The film bubble is collapsed after introducing the plurality of fibers so as to form a fiber-reinforced film. The fiber-reinforced film has a first thermoplastic layer, a second thermoplastic layer, and a plurality of fibers dispersed therebetween. The film may be formed in a bag.

Abstract: A blown-film process for making a fiber-reinforced film comprises providing and melting at least one thermoplastic resin. The at least one thermoplastic resin is extruded through an extension die to form a film bubble. A plurality of fibers is introduced inside of the film bubble. The fibers are distributed inside of the film bubble. The film bubble is collapsed after introducing the plurality of fibers so as to form a fiber-reinforced film. The fiber-reinforced film has a first thermoplastic layer, a second thermoplastic layer, and a plurality of fibers dispersed therebetween. The film may be formed in a bag.

Abstract: A protective armor product comprised of a panel which defines the interior and perimeter profile of the protective armor product. The panel is comprised of a stiff fibrous boardstock material with one or more layers of fibrous felted material of densified needlepunched construction. The fibrous felted material is comprised of a plurality of entangled polymeric fibers where at least a portion of the entangled polymeric fibers are melt fused together such that a plurality of fiber to fiber fusion bonding points are distributed within the fibrous felted material. The stiff fibrous boardstock material is formed into the panels to make the protective armor product.

Abstract: A material and method for insulating and providing a drainage path for a foundation wall includes a non-woven thermoplastic board being for insulating and providing a drainage path for a foundation wall. The non-woven thermoplastic board has a thermal resistance of an R-value per inch thickness of at least 1. The non-woven thermoplastic board also has a vertical drainage ability per inch thickness of at least 135 Gallons/Hour/Lineal-Foot/inch at a pressure of 500 pounds per square foot (psf).

Abstract: A material and method for insulating and providing a drainage path for a foundation wall includes a non-woven thermoplastic board being for insulating and providing a drainage path for a foundation wall. The non-woven thermoplastic board has a thermal resistance of an R-value per inch thickness of at least 1. The non-woven thermoplastic board also has a vertical drainage ability per inch thickness of at least 135 Gallons/Hour/Lineal-Foot/inch at a pressure of 500 pounds per square foot (psf).

Abstract: The present invention relates to a method for removing oil from water or a solid surface. This involves contacting the water or the solid surface with a substance in the form of a sheet and having a high humate level under conditions effective for the substance to absorb oil from the water or the solid surface. The substance, having absorbed oil, is then recovered from the water or solid surface. In an alternative embodiment this method can be carried out where the substance is manure which may or may not be in the form of a sheet.

Abstract: A water vapor barrier material for a building structure includes a base entangled net material and a composite nonwoven. The composite nonwoven includes a film layer with a nonwoven layer on each side of the film layer. The film layer has a water vapor transmission rate of less than 10.0 g-MIL/100-in2/day at a temperature of 100 degrees Fahrenheit and 90 percent relative humidity.