Abstract: The disclosure relates to embodiments of an apparatus for producing polymer composite panels. The polymer composite panels include one or more layers of a polymeric matrix having discontinuous fibers embedded therein. The apparatus has a frame, a deposition bed, and a deposition head configured to move relative to the frame and over the deposition bed. The deposition head includes at least one extruder and a nozzle array. The extruder is configured to force the polymeric matrix and discontinuous fibers through the nozzle array and onto the deposition bed. The deposition head is configured to deposit an entire layer of a polymer composite panel on the deposition bed in a single pass so that the discontinuous fibers are oriented in the direction of the single pass. The disclosure also relates to embodiments of a method of forming a polymer composite panel and to embodiments of a polymer composite panel.

Abstract: At least some embodiments of the present disclosure provide a roofing accessory that includes a radiofrequency radiation shielding non-woven fiber composite material. The radiofrequency shielding non-woven fiber composite material includes a first fiber type that includes a conductive material, where the radiofrequency shielding non-woven fiber composite material has a sufficient amount of the first fiber type so as to result, when the radiofrequency shielding non-woven fiber composite material is positioned on a roof structure, in the radiofrequency shielding non-woven fiber composite material allowing for shielding a predetermined percentage of electromagnetic radiation passing through the roof structure. The radiofrequency shielding non-woven fiber composite material includes a second fiber type that includes a non-conductive material. The first fiber type and the second fiber type are randomly dispersed within the radiofrequency shielding non-woven fiber composite.

Abstract: At least some embodiments of the present disclosure provide a roofing accessory that includes a radiofrequency radiation shielding non-woven fiber composite material. The radiofrequency shielding non-woven fiber composite material includes a first fiber type that includes a conductive material, where the radiofrequency shielding non-woven fiber composite material has a sufficient amount of the first fiber type so as to result, when the radiofrequency shielding non-woven fiber composite material is positioned on a roof structure, in the radiofrequency shielding non-woven fiber composite material allowing for shielding a predetermined percentage of electromagnetic radiation passing through the roof structure. The radiofrequency shielding non-woven fiber composite material includes a second fiber type that includes a non-conductive material. The first fiber type and the second fiber type are randomly dispersed within the radiofrequency shielding non-woven fiber composite.

Abstract: A process for making a multi-ply dispersible wipe includes providing a first web and a second web, each web comprising cellulose fibers; superposing the first web over the second web; applying an aqueous solution to at least the first web; after the aqueous solution is applied to the first web, crimping the second web to the first web to create a composite web; cutting or perforating the composite web to define a plurality of multi-ply wet wipes; and packaging the composite web/wet wipes into a package.

Abstract: A filtration medium useful to remove bacteria and/or inactivate virus in water. Examples of the medium include two outer layers made from cellulose fibers and an inner layer made of packed ceramic granules. Methods for producing the medium are also provided.

Abstract: A process for aligning discontinuous fibers, and composite products and mats comprised of highly aligned discontinuous fibers, including products of the process. Aligned discontinuous fiber composite products include a matrix of fibers, each fiber having a longitudinal fiber axis, the composite comprising a free, uncut edge extending along an edge axis. The longitudinal fiber axis of a majority of the fibers in the composite product are aligned within a predetermined alignment tolerance of an alignment axis non-parallel to the edge axis. Aligned discontinuous fiber mats may have a first areal density of fibers in a first region of the composite located inward relative to the free, uncut edge, and a second area density at or adjacent to the free, uncut edge.

Abstract: A system and method for aligning discontinuous fibers, manufacturing tailored preforms, and composite materials comprised of highly aligned discontinuous fibers.

Abstract: Fiber structures and methods are described that incorporate a body of a micron fiber modified by the attachment of discrete length nano-fibers. Numerous of these modified fiber structures can be assembled into air filter media. Further augmentations of the modified fibers and media can be implemented to improve filtration characteristics.

Abstract: Fiber structures and methods are described that incorporate a body of a micron fiber modified by the attachment of discrete length, crimped nano-fibers. Numerous of these modified fiber structures can be assembled into air filter media. Further augmentations of the modified fibers and media can be implemented to improve filtration characteristics.

Abstract: A reinforced composite panel and method of making the composite panel uses processed natural fibers such as bamboo along with a polymeric material. The method includes the steps of: treating a plant source comprising natural fibers with a solvent and processing the treated plant source. The processing step can include arranging the natural fibers into a sheet-like orientation in a variety of ways. A polymeric material is then applied to the natural fibers to form a composite sheet, and the composite panel can be formed from one or more composite sheets.

Abstract: Disclosed herein are embodiments of a multi-layer nonwoven fiber material, and related methods of manufacturing the material. In one exemplary embodiment, the fiber material includes a first layer of directionally aligned fibers together with a second layer of randomly dispersed fibers dispersed over the first layer. Consistent with one exemplary method for manufacturing a nonwoven fiber material, the method includes dispersing a first plurality of fibers horizontally in one or more predetermined directions, as well as dispersing a second plurality of fibers horizontally in random directions. In such an embodiment, the second plurality of fibers is dispersed over the first plurality of fibers. Moreover, an exemplary embodiment of a roofing shingle employing a nonwoven fiber material as described herein is as disclosed.

Abstract: Disclosed herein are embodiments of a multi-layer nonwoven fiber material, and related methods of manufacturing the material. In one exemplary embodiment, the fiber material includes a first layer of directionally aligned fibers together with a second layer of randomly dispersed fibers dispersed over the first layer. Consistent with one exemplary method for manufacturing a nonwoven fiber material, the method includes dispersing a first plurality of fibers horizontally in one or more predetermined directions, as well as dispersing a second plurality of fibers horizontally in random directions. In such an embodiment, the second plurality of fibers is dispersed over the first plurality of fibers. Moreover, an exemplary embodiment of a roofing shingle employing a nonwoven fiber material as described herein is as disclosed.

Abstract: A dispersible absorbent product having a mechanically weakened multi-layered structure, which comprises at least two mechanically weakened layers joined by a water responsive binder. The mechanically weakened regions enhance the dispersibility of the product in a standard toilet. Additionally, the dispersible absorbent products may be pre-moistened with a composition. The pre-moistened products are stable in storage, easily dispersible down a toilet, and deliver cleaning, conditioning, and like benefits. Methods of making such dispersible absorbent products are also disclosed.

Abstract: Disclosed herein are embodiments of a multi-layer nonwoven fiber material, and related methods of manufacturing the material. In one exemplary embodiment, the fiber material includes a first layer of directionally aligned fibers together with a second layer of randomly dispersed fibers dispersed over the first layer. Consistent with one exemplary method for manufacturing a nonwoven fiber material, the method includes dispersing a first plurality of fibers horizontally in one or more predetermined directions, as well as dispersing a second plurality of fibers horizontally in random directions. In such an embodiment, the second plurality of fibers is dispersed over the first plurality of fibers. Moreover, an exemplary embodiment of a roofing shingle employing a nonwoven fiber material as described herein is as disclosed.

Abstract: Disclosed herein are embodiments of a multi-layer nonwoven fiber material, and related methods of manufacturing the material. In one exemplary embodiment, the fiber material includes a first layer of directionally aligned fibers together with a second layer of randomly dispersed fibers dispersed over the first layer. Consistent with one exemplary method for manufacturing a nonwoven fiber material, the method includes dispersing a first plurality of fibers horizontally in one or more predetermined directions, as well as dispersing a second plurality of fibers horizontally in random directions. In such an embodiment, the second plurality of fibers is dispersed over the first plurality of fibers. Moreover, an exemplary embodiment of a roofing shingle employing a nonwoven fiber material as described herein is as disclosed.

Abstract: A mat containing highly machine direction oriented (90% or greater), discontinuous reinforcement fibers, is produced on inclined wire or rotary paper making machinery. Fibers are first uniformly dispersed in an aqueous medium containing thickeners and wetting agents. In one embodiment, antifoaming agents are also added to prevent floating fibers which entangle and reduce orientation. Thermoplastic fibers or particles may also be included. Stock is brought into an open headbox in a flow pattern which allows the fibers to decelerate before approaching the porous suction belt (wire). As the fibers approach the suction belt, the fibers begin to turn and align in the streamline so as to present one end toward the suction wire. The leading ends of the fibers are gripped by the moving belt which drags the fibers out of the dispersion stock in a straight line. The porous mat produced may be dried and bonded through hot air, heat and/or pressure, or chemical binders.

Abstract: The present invention relates to the manufacture of a multi-layered board having a stable, and moisture-resistant surface. To accomplish this and other advantages of the invention, an improved binder system is used in the production of the surface layers of a multi-layered board which combines an. excellent resin penetration inside the wood constituents of the board's surface layers, with a strength, durability and resistance to ambient water and moisture. The improved binder system used in the production of the board surface layers according to this invention involves contacting wood pieces with a binder composition comprised of a curable powdery aldehyde resin and a curable isocyanate resin in the substantial absence of free water to provide a composite mixture that can be formed into a surface layer for assembly and lamination together with other wood and resin composite layers.

Abstract: A mat containing highly machine direction oriented (90% or greater), discontinuous reinforcement fibers, is produced on inclined wire or rotary paper making machinery. Fibers are first uniformly dispersed in an aqueous medium containing thickeners and wetting agents. In one embodiment, antifoaming agents are also added to prevent floating fibers which entangle and reduce orientation. Thermoplastic fibers or particles may also be included. Stock is brought into an open headbox in a flow pattern which allows the fibers to decelerate before approaching the porous suction belt (wire). As the fibers approach the suction belt, the fibers begin to turn and align in the streamline so as to present one end toward the suction wire. The leading ends of the fibers are gripped by the moving belt which drags the fibers out of the dispersion stock in a straight line. The porous mat produced may be dried and bonded through hot air, heat and/or pressure, or chemical binders.

Abstract: A mat containing highly machine direction oriented (90% or greater), discontinuous reinforcement fibers, is produced on inclined wire or rotary paper making machinery. Fibers are first uniformly dispersed in an aqueous medium containing thickeners and wetting agents. In one embodiment, antifoaming agents are also added to prevent floating fibers which entangle and reduce orientation. Thermoplastic fibers or particles may also be included. Stock is brought into an open headbox in a flow pattern which allows the fibers to decelerate before approaching the porous suction belt (wire). As the fibers approach the suction belt, the fibers begin to turn and align in the streamline so as to present one end toward the suction wire. The leading ends of the fibers are gripped by the moving belt which drags the fibers out of the dispersion stock in a straight line. The porous mat produced may be dried and bonded through hot air, heat and/or pressure, or chemical binders.

Abstract: A paper product and a method of making a paper product with a glabrous surface and adapted for use either dry or for use in a manually pre-moistened condition. The paper product having temporary wet strength exhibiting an initial normalized CD wet tensile strength of at least about 75 g/3 inch strip, preferably 105 g/3 inch strip as measured by the Finch Cup Test 5 seconds after immersion and a subsequent CD wet strength of less than 1/2 as measured 10 minutes after immersion. A temporary wet strength agent comprising uncharged chemical moieties such as aldehydes, and aldehydes containing polymers, polyols and cyclic ureas or mixtures thereof in the range of from about 2 pounds per ton to about 30 pounds per ton is added to the web. Optionally starch and a cationic nitrogenous softener/debonder is added. The starch and softener/debonder are added to assist in tailor making the desired paper product having temporary wet strength.

Abstract: A paper product and a method of making a paper product with a glabrous surface and adapted for use either dry or use in a manually pre-moistened condition. The paper product has temporary wet strength exhibiting an initial normalized CD wet tensile strength of at least about 25 g/1" strip, preferably 35 g/1" strip as measured by the Finch Cup Test 5 seconds after immersion and a subsequent CD wet tensile strength of less than about 2/3 the initial value as measured 30 minutes after immersion. A temporary wet strength agent comprising aldehydic units in the range of from about 2 pounds per ton to about 30 pounds per ton is added to the furnish. A cationic nitrogenous softener/debonder is preferably added to the furnish, in an amount of from about 1 pound per ton to about 6 pounds per ton. The CD dry tensile strength of the paper product is from at least about 133 g/1" up to about 267 g/1", and the tensile modulus is from about 10 to about 32 g/% strain while the GM MMD friction is from about 0.26 to about 0.

Abstract: A multi-ply paperboard comprising at least one ply of conventional cellulose fibers and from about 0.1 to about 6 weight percent of a water-borne binding agent; and at least one ply containing up to 20% of chemically intra-fiber crosslinked cellulosic high-bulk fibers and from about 0.1 to about 6 weight percent of a water-borne binding agent. The water-borne binding agent may be a starch, a modified starch, a polyvinyl alcohol, a polyvinyl acetate, a polyethylene/acrylic acid copolymer, an acrylic acid polymer, a polyacrylate, a polyacrylamide, a polyamine, guar gum, an oxidized polyethylene, a polyvinyl chloride, a polyvinyl chloride/acrylic acid copolymer, an acrylonitrile/butadiene/styrene copolymer or polyacrylonitrile. A method for making the paperboard is disclosed.

Abstract: The improved creped non-laminar singular web structure comprising long fibers and short fibers demonstrated by high TWA and Z peeling. Creping causes a certain portion of long synthetic fibers and short fibers to substantially be oriented in a predetermined vertical or Z direction across the thickness of the web structure. In particular, when a stratified preparation containing wet stiff CTMP fibers is used, the vertically oriented CTMP fibers increase the total water absorption (TWA) of the web structure without collapsing. The high TWA print/double-creped paper products manufactured from the above web structure are suitable for heavy wipe and dry uses.

Abstract: A multilayer headbox of a paper machine for producing a paper web with several layers having different properties, and an appropriate method therefor. In at least one first layer there is adjusted alone the fiber orientation cross profile and in at least one second layer there is adjusted alone the basis weight cross profile.

Abstract: An oriented strand board product is provided. The board is comprised of a baseboard having three wood strand layers, the wood strands being oriented in space with respect to a board-forming machine such that a core layer is comprised of wood strands oriented generally in a random or cross-machine direction and each adjacent layer is comprised of coarse and fine wood strands oriented generally in the machine direction and wherein the wood strands comprising each adjacent layer are formed with the coarsest strands located nearest the core layer and the finest strands are located nearest the outer surfaces of each outer board layer. The OSB board product is clad with a dry felted wood fiber overlay on one planar surface of the baseboard.

Abstract: An oriented strand board (OSB)-fiberboard composite structure is comprised of a baseboard having three wood strand layers, the wood strands being oriented in space with respect to a board forming machine such that a core layer is comprised of wood strands oriented generally in a random or cross-machine direction and each adjacent layer is comprised of coarse and fine wood strands oriented generally in the machine direction. In a preferred embodiment, the wood strands comprising each adjacent OSB layer are formed with the coarsest strands located nearest the core layer and the finest strands are located nearest the outer surfaces of each outer board layer. The OSB-fiberboard composite product is clad with a wood fiber overlay on one major surface of the baseboard. The composite board is manufactured without warping, by providing particular OSB layer thicknesses, such that the lower OSB layer is about 25% to about 35% thicker than the OSB layer bonded to the fiberboard.

Abstract: An oriented strand board product is provided. The board is comprised of a baseboard having three wood strand layers, the wood strands being oriented in space with respect to a board forming machine such that a core layer is comprised of wood strands oriented generally in a random or cross-machine direction and each adjacent layer is comprised of coarse and fine wood strands oriented generally in the machine direction and wherein the wood strands comprising each adjacent layer are formed with the coarsest strands located nearest the core layer and the finest strands are located nearest the outer surfaces of each outer board layer. The OSB board product is clad with a dry felted wood fiber overlay on one planar surface of the baseboard.

Abstract: Novel multi-layer paper and tissue products are provided, which possess strength, softness and absorbency. The products comprise either at least two foam deposited paper layers, wherein the foams have different air contents therein, or foam and water deposited layers. The layers can be deposited at about identical feed pressures from a single headbox while still possessing differing tensile strength ratios. Novel processes for forming such products are also provided.

Abstract: The bulk and absorbency of multi-ply tissue products can be improved by brushing at least one surface of at least one ply of the tissue and plying the tissue product together such that at least one brushed surface is facing inwardly, i.e. is in the middle and not on the outside of the multi-ply product.

Abstract: A non-woven fibrous mat of generally random fiber orientation with built up lines or strips of fiber formed therein directionally oriented to enhance the strength and/or appearance of a mat and a method and apparatus for efficiently producing the same by differentially controlling dewatering in a wet mat process.

Abstract: The invention relates to a ceramic fiber felt or mat having one portion comprising a high temperature resistant ceramic fiber and another portion of lower temperature resistant ceramic fiber. The two portions are joined seamlessly by an intermingling and intimate relationship of the two fiber types during formation of the mat. The invention further provides apparatus for formation of such ceramic fiber composites and further provides for forming such composite ceramic fiber members into modules.

Abstract: A layered paper and method of making it, which paper is characterized by having a soft, relatively untextured smooth velutinous surface defined by a multiplicity of relatively flaccid papermaking fibers having unbonded free end portions of substantial length, and which surface is subjectively discernible by humans as being extremely soft and smooth. Exemplary embodiments include tissue paper, and tissue paper products comprising one or more plies of such paper. The method includes wet laying a layered web which has a relatively low bond surface layer comprising at least about 60% relatively short papermaking fibers, drying the web without imparting substantial texture thereto, breaking sufficient papermaking bonds in the surface layer to generate a velutinous surface having an FFE-Index of at least about 60 and preferably at least about 90, and calendering the dried web as required to provide said surface layer with an HTR-Texture of about 1.0 or less, and more preferably about 0.

Abstract: This invention comprehends a machine for producing a composite laminate structure wherein one layer is a base material, such as a non-woven fabric, a second layer, interspersed with the first layer, is substantially a two dimensionally randomly oriented fiber layer. The fibers are bonded to the first layer by resin which is applied from underneath the first layer so as not to disturb the orientation of the fibers. Also comprehended is a method of making such a composite laminate structure.