Abstract: A system for producing three dimensional components by bonding together successive layers of a porous material with droplets of a binder material. A binder printhead has an array of nozzles which controllably supply jets of binder material droplets to the layers of porous material. The printhead is scanned in a raster scan fashion over each layer of porous material along a first scan axis in one direction to provide first fast scanning paths of droplets. The printhead is then moved laterally of such one direction and is then moved along the fast-scan axis in the opposite direction to provide second fast scanning paths of droplets which are interlaced with the first scanning paths. The supply of the droplets to the porous material can be controlled so as to control the overlapping thereof to produce various desired surface and interior characteristics of the components.

Abstract: Shaped bodies such as board can be made from a mixture of comminuted vegetable matter and an isocyanate binder by forming the mixture with a moisture content in excess of that required to cure the binder, then coating a support for the mixture with a layer of a liquid parting agent, depositing the mixture on the support, coating the mixture with another film of the parting agent and hot pressing the mixture to form the board.

Abstract: A molded, self-supporting, composite part or panel for automotive and similar applications comprises a vapor impervious wood fiber filled polymeric (preferably polypropylene) sheet adhered to one major face of a corrugated paperboard medium and a layer of fibrous insulation (preferably glass fiber) or a second wood fiber filled polymeric sheet adhered to a second major face of the corrugated paperboard medium. The sheet and corrugated medium provide the structural strength for the composite and the fibrous insulation, when used, provides the composite with good sound absorption properties. The wood fiber filled polymeric sheet is formed during the molding process from a wood and polymeric fiber sheet. The heat and pressure of the molding process cause the polymeric fibers to melt and flow about the wood fibers to form the wood fiber filled sheet and bond the sheet securely to the corrugated medium.

Abstract: A molded core component includes a center plane piece and at least one wall extending from the center plane piece. The wall preferably includes contours which form a multiplicity of pods, cells, or protrusions integral with the center plane piece. The core component is preferably inserted into the space or void formed by two prefabricated molded fiberboard doorskins, wherein the center plane piece lies substantially in the central plane of the door product. Processes for the production of a molded core component and a composite door product are also disclosed.

Abstract: A distinctive method and apparatus (20) for forming a composite fibrous web (22) includes a web supply (24, 25), which provides at least two appointed fiber layer sections (26, 28) of desired fiber material. Each of the layer sections (26, 28) has a selected composition. A fiberizer (30) disintegrates each of the fiber layer sections (26, 28) into individual, laterally adjacent fiber streams (32, 33) while substantially maintaining a lateral separation of the fiber streams while the fiber streams (32, 33) are moving through the fiberizer (30). A directing channel (34) delivers the fiber streams (32, 33) from the fiberizer (30) to a forming chamber (40). The forming chamber (40) is configured to substantially maintain the separation of the fiber streams.

Abstract: A method for manufacturing a sandwiched sheet includes grinding the natural plants into short segments and adding and mixing adhesive material into the short natural plants for forming a base material which is then heated and extruded for forming two or more boards. A woven layer of long fiber plants is engaged between the boards and includes a number of openings for allowing the base material of the boards to be filled into the openings of the woven layer and for forming a reinforced sandwiched sheet. Two layers of non-woven fabric material are engaged on the boards for forming smooth outer surfaces.

Abstract: A method for manufacturing a container from husk includes the steps of comminuting the husk into powder form, mixing the powder with an edible adhesive, with the introduction of steam, to form a paste, forming a blank from the paste, shaping the blank into a primary semi-product, re-shaping the primary semi-product to force the paste to flow and fill into cracks formed on the primary semi-product during the shaping step to form a secondary semi-product, drying the secondary semi-product and applying a surface coating to the dried product and then drying the surface coating.

Abstract: An apparatus for supplying particles and/or granules to form a layer of prescribed thickness onto a given surface includes endless pattern-forming device having a plurality of spaces, a device for supplying particles and/or granules into the spaces via a control member provided on the particle or granule-supplying device, a device for temporarily retaining the supplied particles and/or granules in the spaces, and a device for releasing the temporarily retained particles and/or granules onto the given surface. A patterned shaped article is produced by a method using the apparatus. The method includes supplying dry particles and/or granules for a pattern course into the spaces, temporarily retaining the supplied particles and/or granules in the spaces, releasing the temporarily retained particles and/or granules onto the given surface, and allowing the released particles and/or granules to set on the given surface.

Abstract: A method of forming a composite material including the steps of: providing a surface against which the composite material can be molded; providing a plurality of discrete filler particles; placing a plurality of discrete filler particles against the surface; preventing the particles from shifting freely along the surface; directing a liquified matrix material against the particles on the surface; and solidifying the matrix material to unite the discrete particles and matrix material into a composite structure.

Abstract: A composite powder specially adapted for use in selective laser sintering is disclosed. The composite powder includes a polymer powder dry mixed with a reinforcement powder, where the polymer powder has a melting temperature substantially lower than that of the reinforcement powder. In the case where nearfully dense parts are to be formed, the first constituent powder is preferably a semi-crystalline powder, for example nylon 11, of a composition suitable for forming near-fully dense parts when used unblended in selective laser sintering; if porous parts are desired, the polymer powder is an amorphous powder, such as polycarbonate, polystyrene, acrylates, and styrene/acrylate copolymers. The reinforcement powder is preferably microspheres of glass, preferably coated to enhance wetting and adhesion with the polymer powder when selective laser sintering is performed.

Abstract: The apparatus is provided to make a melt blown fibrous medium and includes first and second melt blowing dies for respectively issuing first and second streams of melt blown fibers along first and second melt blown paths. The first and second streams are issued on a forming surface where the streams are collected to form a melt blown fibrous medium. A movable transfer surface is interposed between the first die and the forming surface in the first path so that the first stream of melt blown fibers impinges on the transfer surface in advance of the forming surface such that the first stream is transferred to and brought into contact with the second stream of melt blown fibers on the forming surface.

Abstract: In an apparatus for producing a three-dimensional object by laser sintering the object is produced by successive solidification of layers of a powder material at points corresponding to a cross-section of said object using radiation for solidifying said powder material. The apparatus includes a support having a substantially plane upper side for supporting the object, a material applying device for applying a layer of the material onto the upper side or onto another layer formed on the upper side, and a solidification device for solidifying a layer of the material by irradiation. The material applying device has a coating device and a drive for displacing the coating device in a direction parallel to the upper side of the support.

Abstract: A hard-faced ceramic fiber module is formed by providing a ceramic fiber sheet that is folded upon itself to form a first surface having adjacent folds and intermediate valleys by impregnating the first surface with an aqueous colloidal silica suspension, covering said impregnated first surface with a layer of a mixture of ceramic fibers in an aqueous colloidal suspension, compressing said layer, freezing said module and then heating the same to remove substantially all of the water.

Abstract: The cartridge filter of the present invention is a filter comprising a wound and laminated composite non-woven fabric containing heat fusible fibers, wherein the delamination strength between layers of the laminated composite non-woven fabric of said filter increases continuously or discontinuously from the outer layer toward the inner layer, the delamination strength of the inner layer-exceeds 1000 gf/5 cm, and the delamination strength of the outer layer is 5 to 1000 gf/5 cm. This cartridge excels in filtering life, filtering accuracy, and pressure resistance.

Abstract: An apparatus and method for distributing pressurized fiber attenuating fluid through a melt blowing multi-headed die body uniformly and contaminant filtered with a minimum of energy loss before reaching the fluid attenuating outlets of the die body.

Abstract: A decorative construction material such as a glass tile is produced from recycled glass granulate, and exhibits a smooth, external surface substantially free from defects on one side of the tile. One or two layer tiles may be produced. A binder, together with control of the maximum temperature and temperature gradient in the layers, if applicable, is used during manufacture to ensure a substantially flawless outer surface.

Abstract: An expanded, memory molded, increased density, highly impact-resistant polystyrene construct, and method of making the construct. The construct is formed by molding pre-expanded non-equilibrated polystyrene beads to a first volume, cooling rapidly, and then compression molding to a final, smaller volume. The resultant constructs have increased density, and high impact strength without increase in embrittlement. Also, the construct has "memory" in the sense that it returns substantially to its original shape after impact.

Abstract: The invention relates to a process for the production of porous shaped articles having a predetermined pore structure by shaping a composition which can undergo plastic deformation and then be solidified, which is characterized in that the shaped article is built up in the form of layers by repeated sequence of the stepsA. Production of a layer of the composition structured in an image-wise manner corresponding to the pore system, andB. Solidification of the layer the image structures of the individual layers being transferred from corresponding models. This process can preferably be used for the production of shaped articles having a three-dimensionally interconnecting pore system, and in particular for the production of shaped implants having the pore system of natural bone.

Abstract: Bicomponent moulded article made of polytetrafluoroethylene (PTFE) which, in the manner of the side-by-side type, is composed of two PTFE components which shrink under the effect of heat and differ in their hot-air shrinkage by at least 1%. A preferred embodiment is in the form of a fibre which can be crimped under heat treatment. (FIG.

Abstract: A process which permits the production of mouldings which have little odor and comprise fibrous semifinished products to which heat-curing novolak resins have been added and which are suitable for lining heat-emitting and/or sound-emitting vehicle parts, in which their binders are completely and uniformly crosslinked. The odor emission, in particular the formaldehyde emission, is thus reduced. This process furthermore permits the production of products having an unusually large layer thickness. The homogeneous polymerisation reaction is achieved by the use of a hot fluid in the form of a dry, saturated steam and under elevated pressure.

Abstract: A method of making dual or multi-porosity porous plastic strips comprising placing a first quantity of plastic granules into a mold, and placing a second or additional quantities of plastic granules into the mold above the first quantity. The particle sizes of each of the quantities of granules placed into the mold are different from the particle sizes of all the other quantities of granules in the mold. The granules are subjected to heat and pressure so as to fuse them together into a self-sustaining porous plastic billet. The billet has a number of fused-together regions corresponding to the number of quantities of granules placed into the mold. The billet is sliced in a direction transverse to the planes containing the interfaces between the regions of the billet so as to create strips, each strip comprising interconnected regions have porosities which differ from one another. The mold may be cylindrical and the strip created by skiving it off the cylindrical surface of the billet.

Abstract: Disclosed is an adsorbent fibrous nonwoven structure composed of a matrix of pulp fibers having a first exterior surface and a second exterior surface; and an adsorbent material integrated into the pulp fiber matrix so that the concentration of adsorbent material adjacent the first exterior surface of the nonwoven structure is at least about 60 percent, as determined by optical image analysis, and the concentration of adsorbent material adjacent the second exterior surface is less than about 40 percent, as determined by optical image analysis. This adsorbent nonwoven structure provides useful strength and low-lint characteristics. The fibrous nonwoven structure of the present invention may be laminated together or to surfaces of other materials.

Abstract: A process for continuously preparing low density detergent agglomerates is provided. The process comprises the steps of: (a) spray drying an aqueous mixture of sodium sulfate, sodium carbonate and a minor amount of a surfactant so as to form spray dried granules containing an inorganic double salt having the formula Na.sub.2 SO.sub.4 .multidot.Na.sub.2 CO.sub.3 and a minor amount of the surfactant; (b) agglomerating the spray dried granules with a detergent surfactant paste or precursor thereof and adjunct detergent material initially in a high speed mixer and subsequently in a moderate speed mixer to obtain detergent agglomerates, wherein the adjunct detergent material includes an adjunct sodium carbonate material; and (c) drying or cooling the detergent agglomerates so as to form the detergent composition having a density of below about 500 g/l.

Abstract: The present invention provides a polyethylenic foaming composition comprising (a) 100 parts by weight of an ethylenic copolymer having glycidyl groups consisting of 20 to 99.9% by weight of ethylene units, 0.1 to 30% by weight of a unit of a glycidyl ester of an unsaturated carboxylic acid or an unsaturated glycidyl ether, and 0 to 50% by weight of ethylenically unsaturated ester units other than a glycidyl ester, (b) 0.1 to 30 parts by weight of a carboxylic acid having 2 or more carboxyl groups and a molecular weight of 1500 or less, and (c) 0.1 to 20 parts by weight of a foaming agent of a thermal decomposition type. The present invention also provides a polyethylenic foam molded from said foaming composition.

Abstract: A molded composite product includes a resinous core layer containing reinforcement fibers, and a resinous surface layer which is substantially free of reinforcement fibers, where the resinous surface layer includes a nonresinous additive at a concentration, measured as a weight percentage of the resinous material in the surface layer, which is higher than the concentration of the additive in the resinous core layer, measured as a weight percentage of the resinous material in the core layer.

Abstract: An apparatus and process for making metal oxide sputtering targets from volatile and thermally unstable metal oxide powder by enveloping the metal oxide powder in at least one layer of a barrier material while the powder is hot-pressed using a graphite die assembly.

Abstract: A method of making a three dimensional object by depositing material in a predetermined pattern on a receiving surface, and introducing a predetermined porosity into the object being formed by positioning the deposited material so as to introduce pockets of air or other fluid into the part, and by adjusting the rate at which the material is dispensed from the dispenser. Optimal porosities in the object to be built depend upon the shape of the material when it is dispensed, but range generally from 1% to 26%.

Abstract: An inorganic constructional board for use as wall backing material or the like comprises a middle layer portion (1a) formed mainly of inorganic foamed material with an adequate quantity of fibrous material and binder added thereto, and outer layer portions (1b) placed on both surfaces of the middle layer portion (1a), the outer layer portion being formed mainly of mineral fiber material and inorganic powder material with binder added thereto. The middle layer portion (1a) has a specific gravity of less than 0.4, and the outer layer portions (1b) have a specific gravity of more than 0.7. Therefore, the board is more lightweight than a plaster board and has performance characteristics equivalent to or better than those of the plaster board.

Abstract: A method of bonding various materials, such as foam materials, to thermoplastic resins using a silane composition is provided. The thermoplastic resin is doped with a silane by washing the thermoplastic resin in a silane solution and then evaporating the solution from the resin. The silane-doped thermoplastic resin is then melted and formed into a polymeric article. In one embodiment, a polyurethane foam can then be sprayed onto the polymeric article. As the foam forms on the surface of the article, it bonds with silane trapped within the thermoplastic resin. In one embodiment, the polymeric article can be formed through a rotational molding technique. Through the process of the present invention, many useful articles can be formed such as polymeric pallets, water craft devices, thermocoolers and the like.

Abstract: A method of manufacturing a composite article having a front face containing a visible icon, which front face may be planer or arcuate. The method includes the steps of forming a core having perforate and imperforate portions in the core thereby creating a stencil defining the icon; forming an anvil having supporting surfaces in the shape of the icon and seated in supporting contact with the stencil; and forming the front layer of the article by injection molding an opaque plastic covering the front face of the core except for the imperforate portions of the stencil defining the icon. The composite article includes a core having a front face and a rear face with perforate and imperforate portions of the core forming a stencil defining the icon. An opaque plastic layer is formed on the front face of the core and covers the stencil except for the icon portion thereof.

Abstract: There is provided by this invention a least three integrated regions, each region having wherein the density and fluid affinity of the composite continuously increases from top to bottom thereby facilitating effective fluid transport and efficient utilization of storage capacity. An additional layer of SA and tissue may be provided to the absorbent product to provide an absorbent structure with dry feel and low stain. Methods of forming integrated, multi-layered absorbent composites and structures comprising at least three regions wherein each region has distinct density and fluid affinity gradients and wherein the density and fluid affinity of the composite continuously increases from top to bottom, are also provided herein.

Abstract: Fiber reinforced composite products of enhanced interlaminar ply strength and processes of producing same. In forming the products, layers of fibrous reinforcing material and resinous matrix material are established. The matrix material contains unset resin and short fibers of an average particle length of 0.2-0.6 mm in a weight ratio of short fibers to resin in the range of 0.4-1. The reinforcing material comprises fibers of a length substantially greater than the length of the short fibers in the matrix material. The fiber and matrix layers are integrated in order to cause the resin and short fibers which comprise the strengthened matrix material to enter into the interstitial spaces of the longer fiber reinforcing material. Thereafter, the matrix resin is solidified in order to arrive at the fiber reinforced composite product.

Abstract: The present invention is directed to producing a smooth hard coating on a wood substrate. A layer of a foamed polymerized latex emulsion is applied on the surface of a wood substrate, such as an oriented strand board. The layer is dried, crushed and then cured to form the coating. If desired the cured coating may be provided with a post cure heat treatment to improve its hardness. The present invention is also directed to applying and drying the layer of the foamed polymerized latex emulsion on a mat of wood fibers or flakes and then crushing and curing the crushed layer and the mat into a hardboard having a smooth hard coating. The coating of the present invention is useful as a sealer coat on a wood substrate. By adding pigment to polymerized emulsion, the sealer coat can be used to provide a finish coat on the wood substrate.

Abstract: A method for controlling chemical distribution of substances in a solid state (and products produced thereby), the method comprising the steps of mixing particles of a first powder and a triggerable granule facilitator to form first microcapsules, the first microcapsules each having a core of one of the particles and a cladding of the facilitator; and triggering the facilitator while dry mixing the microcapsules to form substantially spherical granules of the microcapsules, the granules each having a controlled chemical distribution.The method also includes the steps of mixing particles of a second powder with the facilitator to form second microcapsules, the second microcapsules each having a core of one of the particles of the second powder and a cladding of the facilitator; and then mixing the first and the second microcapsules prior to said triggering step.

Abstract: A patterned shaped article is produced by a method which includes the steps of supplying a first material onto a given surface until the first material forms a layer of predetermined thickness, removing part of the layer to form at least one concave portion in the layer, filling the at least one concave portion with at least one kind of second material different in color and quality from the first material, and causing the first and second materials to set into an integral mass. When the first material is dry, the second material may be either dry or wet. When the first material is wet, the second material is dry and the moisture of the first wet material is absorbed before the step of removing part of the layer of the first material.

Abstract: A rapid prototyping process is provided by which prototype components can be fabricated that are suitable for conceptual evaluations. The rapid prototyping process of this invention is more efficient than comparable prior art processes, in that the previous requirement to completely process a prototype article within a single process chamber is eliminated, such that different process steps can be conducted simultaneously on different articles within a single process system. The process entails the steps of forming a prototype within a process chamber that generates the prototype through successively depositing and sintering individual layers of a powder material that fuses together so as to form the prototype. The prototype is then removed from the process chamber and cooled within a separate cooling chamber through which a nonoxidizing cooling medium flows.

Abstract: A method of producing a patterned shaped circle includes the steps of forming a course of dry particles on a base surface; using an air flow controller having either a suction port or a blow port or both a suction port and a blow port to cause an air flow to form a cavity in the dry particle course by removing a part of the particles thereof under the control of at least one parameter among air pressure, air flow rate, air flow speed, air flow direction, air flow pulsation, air flow intermittence, suction port size, blow port size, suction port position and blow port position; charging the cavity with a different type of dry particles; and allowing the particles to set into an integral mass.

Abstract: Containers, which are impervious to hydrocarbon vapors, in particular to fuel vapors, and comprise an outer shell of plastic material, which is coated with a polyamide layer at least on the surface in contact with the fuel.Said containers are used in the sector of the fuel industry, in particular in the automotive industry, as tanks for automobiles and motor vehicles.

Abstract: A multilayer nonwoven thermal insulating batt is provided. The batt comprises multiple layers of webs, each web being a blend of 5 to 100 weight percent bonding staple fibers and 0 to 95 weight percent staple fill fibers, the bonding fibers bonded to other bonding fibers and fill fibers at the points of contact to enhance the structural stability of the layers of the batt. Also provided is a method of making the thermal insulating nonwoven multilayer batt comprising the steps of: (a) forming a web of bonding staple fibers and staple fill fibers; (b) subjecting the web to sufficient heat to cause bonding of the bonding staple fibers to other bonding staple fibers and staple fill fibers at points of contact within the web to stabilize the web; and (c) forming a batt of multiple layers of said webs.

Abstract: A method and apparatus for producing plastic products from waste materials by: cutting into pieces a thermoplastic material having a loss factor higher than 0.005 such as to have a high absorbence of radio-frequency radiation, mixing the pieces with at least one other particulate material, depositing the mixture on a supporting surface; applying radio-frequency radiation to the mixture sufficient to soften mainly the outer surfaces of the pieces of thermoplastic material by dielectric heating, while applying pressure to the mixture to bond the mixture together by sintering; and removing the sintered mixture from the supporting surface.

Abstract: There is provided by this invention a least three integrated regions, each region having wherein the density and fluid affinity of the composite continuously increases from top to bottom thereby facilitating effective fluid transport and efficient utilization of storage capacity. An additional layer of SA and tissue may be provided to the absorbent product to provide an absorbent structure with dry feel and low stain. Methods of forming integrated, multi-layered absorbent composites and structures comprising at least three regions wherein each region has distinct density and fluid affinity gradients and wherein the density and fluid affinity of the composite continuously increases from top to bottom, are also provided herein.

Abstract: An embossed sheet coated at least partially with expanded graphite and suitable for use as a gasket or as a component layer of a gasket is manufactured by positioning a planar metallic sheet between an upper embossing die and a lower embossing die with a layer of particles of expanded graphite between one of said dies and a surface of the sheet. One of the dies has a protuberance to emboss a ridge into the sheet while the other die has a recess to receive the ridge. The method also comprises pressing the dies together to cause the particles to coalesce and form a coating attached to the sheet while simultaneously embossing said ridge into the sheet.

Abstract: Disclosed is an adsorbent fibrous nonwoven structure composed of (1) a matrix of pulp fibers having a first exterior surface and a second exterior surface; and (2) an adsorbent material integrated into the pulp fiber matrix so that the concentration of adsorbent material adjacent the first exterior surface of the nonwoven structure is at least about 60 percent, as determined by optical image analysis, and the concentration of adsorbent material adjacent the second exterior surface is less than about 40 percent, as determined by optical image analysis. This adsorbent nonwoven structure provides useful strength and low-lint characteristics. The fibrous nonwoven structure of the present invention may be laminated together or to surfaces of other materials.

Abstract: A forming station used to make a substrate. The forming station has a forming chamber which deposits particles and fibers from an air carrier onto a forming screen movable relative to the forming chamber. Inside the forming chamber is at least one baffle, which creates a velocity gradient and low pressure zone for the air carrier. Different sized components of the substrate have different momentums, and thus are differently affected by the velocity gradient and low pressure zone. This difference causes the different sized components to be sorted according to size. The sorted components are then distributed according to size within the substrate.

Abstract: A process for preparing shaped articles comprises the steps of:(a) mixing a water curable binder with vegetable particulate material to form a first mixture, the moisture content of said first mixture being insufficient to cure said binder prior to said mixture being placed in a mold;(b) feeding said first mixture to a mold having molding plates, said molding plates and said first mixture defining an interface;(c) providing water to at least a portion of said interface, the amount of water added at said interface, in conjunction with the moisture content of said first mixture, being sufficient to cure said binder; and,(d) subjecting said first mixture to elevated temperatures and pressures.

Abstract: A molded wood composite article man-made from wood fibers or wood particles on at least an upper, molded surface of the article, and a method of manufacturing the article to include a relatively uniform density, detailed design contours and textured aesthetics on one or more molded depression-interior inclined surfaces, while preventing embrittlement, softness and blistering of the article along the depression-interior inclined surfaces. These attributes are achieved by molding one or more depressions into an initially planar layer of cellulosic material, wherein the molded depressions have one or more inclined walls that have upper surfaces, along essentially an entire inclined span, that include detailed design contours, including adjacent curved and planar portions, e.g., bead and cove.

Abstract: A method of producing a pattern shaped article includes the steps of forming at least two different courses of dry particles overlaid on a base surface; using an air flow controller having either a suction port or a blow port or both a suction port and a blow port to effect an air flow to form a cavity corresponding to a pattern expression in at least a lower dry particle course by removing a portion of the lower dry particle course under control of at least one parameter among air pressure, air flow rate, air flow speed, air flow direction, air flow pulsation, air flow intermittence, suction port size, blow port size, suction port position and blow port position; collapsing particles of an upper dry particle course of a different type of dry particles into the cavity and allowing the particles to set into an integral mass.

Abstract: A method of manufacturing a three-dimensional fabric of the type which may be used in absorbent garments, dressings or the like involves the use of an apertured collector element which has a predetermined three-dimensional shape. The method involves positioning material adjacent to one side of the apertured collector element and developing a pressure differential between the one side of the apertured collector element and a second, opposite side to force the fabric material against the apertured collector element. The material, which has conformed to the shape of the collector element, is then solidified into its intended three-dimensional shape.

Abstract: A system and a method for manufacturing plastic structures using ultra-violet curable plastic materials is provided. Specifically, the present invention applies a resin layer to a conveyor belt. The resin layer is then warmed and various types of reinforcing elements are added. The conveyor belt with the resin layer is then passed through a forming apparatus where a predetermined shape is imparted to the layer. The predetermined shape become permanent as the resin layer is exposed to ultra-violet radiation which cures and hardens the resin layer. The completed structure is then extracted from the process.

Abstract: A method for producing a material for a fiber-reinforced composite article is disclosed which comprises preparing an apparatus composed of a belt and at least one fiber-separating and throwing device, setting the belt in motion and the roller in rotation, feeding a mixture of matrix thermoplastic resin fibers (a) and reinforcing fibers (b) to the roller, causing the roller to separate the fibers and throw the separated, fibers, and allowing the thrown fibers to pile up on the moving belt, thereby giving rise to a mat wherein the ratio of the fibers (a) and (b) successively increases or decreases in the direction of thickness of the mat.