Abstract: A method of consolidating thermoplastic fibrous layers. The method begins with providing a plurality of fibers, where the fibers have a core with an exterior surface portion comprising polypropylene and a first layer disposed on at least a portion of the core. The first layer contains a first polymer, where the first polymer contains at least 70% ?-olefin units and is characterized by a melting temperature less than the melting temperature of the exterior surface of the core. These fibers are formed into a fibrous layer. Next, a second layer is applied to the fibrous layer such that the second layer covers at least a portion of the first layers of the fibers. The second layer contains a second polymer being a co-polymer having at least 50% ?-olefin units which is characterized by a number-average molecular weight of about 7,000 g/mol to 50,000 g/mol, a viscosity of between about 2,500 and 150,000 cP measured at 170° C.

Abstract: A consolidated fibrous structure including a multiplicity of fibrous layers. The fibers of each fibrous layer contain a core, a first layer and a second layer. The core has an exterior surface portion containing polypropylene. The first layer is disposed on at least a portion of the core and contains a first polymer. The first polymer contains a polymer having at least 70% ?-olefin units and is characterized by a melting temperature lower than the melting temperature of the exterior surface portion of the core. The second layer is disposed on at least a portion of the first layer and contains a second polymer. The second polymer contains a co-polymer having at least 50% ?-olefin units and is characterized by a number-average molecular weight of about 7,000 g/mol to 50,000 g/mol, a viscosity of between about 2,500 and 150,000 cP measured at 170° C., and a melting temperature lower than the melting temperature of the exterior surface portion of the core.

Abstract: A consolidated fibrous structure including a multiplicity of fibrous layers. The fibers of each fibrous layer contain a core and a skin layer. The core has an exterior surface portion containing polypropylene. The skin layer is disposed on at least a portion of the core and contains a first polymer and a second polymer. The first polymer contains a polymer having at least 70% ?-olefin units and is characterized by a melting temperature lower than the melting temperature of the exterior surface portion of the core. The second polymer contains a co-polymer having at least 50% ?-olefin units and is characterized by a number-average molecular weight of about 7,000 g/mol to 50,000 g/mol, a viscosity of between about 2,500 and 150,000 cP measured at 170° C., and a melting temperature lower than the melting temperature of the exterior surface portion of the core. The viscosity of the second polymer is not greater than about 10 percent of the viscosity of the first polymer measured at 170° C.

Abstract: An odiferous organic compounds cover having an inner surface and an outer surface. The cover contains a thermoplastic non-woven layer having a first side and a second side and comprising thermoplastic fibers. The first side of the non-woven layer forms the inner side of the cover, has a contact angle with water greater than about 70°, and is non-wicking. The cover contains a UV barrier layer on the second side of the non-woven layer, where the UV barrier layer contains a UV blocking polymer which blocks at least 50% of UV(C) energy. The UV barrier layer has a thickness of between one to three times the diameter of the thermoplastic fibers of the non-woven layer and the UV barrier layer comprises discontinuities forming microchannels though the layer thickness. The cover also contains an odor mitigation layer on the UV barrier layer on the side of the barrier layer opposite the non-woven layer.

Abstract: A method of fabricating a porous, fiber-reinforced thermoplastic sheet having increased lofting properties is provided. The method includes adding reinforcing fibers having an average length of about 5 mm to about 50 mm, and thermoplastic resin powder particles to an agitated aqueous foam to form a dispersed mixture, laying the dispersed mixture of reinforcing fibers and thermoplastic resin particles down onto a support structure, evacuating the water to form a web, generating a z-axis orientation of a portion of the reinforcing fibers, heating the web above the glass transition temperature of the thermoplastic resin, and pressing the web to a predetermined thickness to form a porous thermoplastic composite sheet having a void content of about 1 percent to about 95 percent.

Abstract: A composite sheet material that includes at least one porous core layer including a thermoplastic material and from about 20 weight percent to about 80 weight percent fibers based on a total weight of the porous core layer, and at least one skin covering a surface of the core layer. The skin includes at least one of a thermoplastic film, a fiber based scrim, a non-woven fabric, and a woven fabric.

Abstract: A shaped composite article is prepared by a process wherein an aesthetic laminate having a clear outer arylate layer and a colored compatible resin layer is thermoformed into a desired shape, and then compression molded together with a reinforced resin material containing compatible resin to form a color composite of the desired shape having an outer layer of clear arylate polyester polymer with the compatible resin layer forming an adherent bond with the compatible resin in the resin reinforced material.

Abstract: A composite sheet material that includes at least one porous core layer including a thermoplastic material and from about 20 weight percent to about 80 weight percent fibers based on a total weight of the porous core layer, and at least one skin covering a surface of the core layer. The skin includes at least one of a thermoplastic film, a fiber based scrim, a non-woven fabric, and a woven fabric.

Abstract: A shaped composite article is prepared by a process wherein an aesthetic laminate having a clear outer arylate layer and a colored compatible resin layer is thermoformed into a desired shape, and then compression molded together with a reinforced resin material containing compatible resin to form a color composite of the desired shape having an outer layer of clear arylate polyester polymer with the compatible resin layer forming an adherent bond with the compatible resin in the resin reinforced material.