A repulpable insulated container assembly having a container formed of paper such as corrugated cardboard or varying paper materials and defining an interior; and a repulpable insert placed within the interior of the container and formed of a first paper layer; and a paper fiber pad coupled to the first paper layer.

A method of manufacturing a composite part comprising a core and at least one skin region formed of a low friction UHMWPE skin polymer attached thereto, by: a) providing a mold with a heatable mold cavity; b) loading into the mold cavity UHMWPE powder followed by a core element having a surface with at least one contacting region provided with a plurality of anchoring sites, loading onto the core element, a layer of UHMWPE in powder form adjacent the contacting region, and applying a heat pressing step to melt the skin polymer powder to form a molten skin polymer matrix, and cooling to solidify the skin polymer matrix forming a skin region mechanically engaged into anchoring sites of the core element.

A process of forming the fiber preform includes providing a substrate, applying a first layer of a fiber bundle to the substrate in a predetermined pattern having a principal orientation, stitching the first layer of the fiber bundle to the substrate using a thread, building up subsequent layers of the fiber bundle from the first layer, and stitching each of the subsequent layers to a preceding layer using the thread. A process of forming a unitary reinforced composite material includes the fiber preform. The process of forming a unitary reinforced composite component includes placing the fiber preform a mold platen, heating the perform to promote fusion of the thermoplastic fibers therein, cooling the perform until solidified with contours of the component, and removing the vehicle component from the mold platen.

A repulpable insulated container assembly having a container formed of paper such as corrugated cardboard or varying paper materials and defining an interior; and a repulpable insert placed within the interior of the container and formed of a first paper layer; and a paper fiber pad coupled to the first paper layer.

A method for producing an insulation material is described herein. The method includes mixing cellulose reinforcement fibers with thermoplastic binder fibers to form a mixture. In addition, the method includes applying heat to the mixture to melt the thermoplastic binder fibers such that the thermoplastic binder fibers bind the cellulose reinforcement fibers together to form a batt. The thermoplastic binder fibers make up about 0.5% to about 25% by weight of the batt. Furthermore, the method includes slicing the batt along a horizontal plane to form a first pad having a first thickness and a second pad having a second thickness. Each of the first and second thicknesses is greater than or equal to about 1/16 of an inch.

A repulpable insulated container assembly having a container formed of paper such as corrugated cardboard or varying paper materials and defining an interior; and a repulpable insert placed within the interior of the container and formed of a first paper layer; and a paper fiber pad coupled to the first paper layer.

Systems and methods are provided for fabricating a laminate. One method includes laying up a first set of layers comprising tows of unidirectional thermoplastic fiber-reinforced material for the laminate, and laying up a second set of layers comprising tows of braided thermoplastic fiber-reinforced material for the laminate.

A repulpable insulation material includes a batt formed of a mixture of thermoplastic binder fibers and cellulose fibers bound together by the thermoplastic binder fibers. The thermoplastic binder fibers make up about 0.5% to 25% by weight of the batt. The repulpable insulation material have a weight within a range from 1000 GSM to 1600 GSM. Subjecting the repulpable insulation material to a repulpability test produces greater than 85% fiber yield.

The present disclosure provides a polymeric membrane. The polymeric membrane includes a first thermoplastic elastomer layer that comprises a styrenic thermoplastic. The thermoplastic elastomer layer has a foam structure. The polymeric membrane can further include an optional second thermoplastic elastomer layer in contact with the first polyolefin layer.

The present disclosure provides a polymeric membrane. The polymeric membrane includes a first thermoplastic elastomer layer. The thermoplastic elastomer is a styrenic thermoplastic. The polymeric membrane can further include an optional second thermoplastic elastomer layer in contact with the first polyolefin layer.