Thermoplastic composite preforms for continuous fiber thermoplastic composite structural profiles and a system and method of manufacture for structural profiles utilizing thermoplastic filaments comingled with high strength fibers such as carbon fibers and braided into complex preforms suitable for automated press forming is disclosed. Utilizing flexible preforms in lieu of conventional rigid thermoplastic pre-preg material forms allows for manufacture of complex shapes, including both straight and curved shapes by an automated process.

A method and system for producing an insulated mailer and an insulated box having an insulative paper fiber pad substructure with a density of less than about 10 pounds per cubic foot. The insulative paper fiber pad has entangled reinforcement fibers. A method of forming an insulative paper fiber pad using recycling-compatible or water soluble adhesive and paper layers is provided.

The present invention relates to a manufacturing method of a natural fiber composite material for injection molding using a reduced nozzle heating jig, and particularly, to a manufacturing method of a natural fiber composite material for injection molding using a reduced nozzle heating jig, which is configured to include: combining natural fibers and synthetic fibers (S1); heat-pressing the combined ply yarn while passing through a reduced nozzle heating jig 100 and melting and pressing the synthetic fibers and fusing the synthetic fibers to the natural fibers (S2); and palletizing the mixed ply yarn (S3).

A composite manufacturing method includes the step of drawing a nonwoven fabric formed of continuous fibers through a slurry of discontinuous fibers suspended in a dispersive liquid to yield a fiber-modified interlayer comprising a network of said discontinuous fibers attached to said nonwoven fabric.

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 forming a shipping container includes mixing paper fibers with a binder fiber to form a mixture; disposing the mixture onto a surface to form a layer of the mixture; applying heat to form a paper fiber batt from the mixture having a fixed width and fixed length; and inserting the paper fiber batt within an interior of a corrugated box.

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 weight and noise reducing glovebox assembly made of an inner glovebox bin composed of a pair of thermopolymer fiber layers that work in concert to absorb noise and isolate noise and vibration providing a glovebox with improved NVH characteristics. The glovebox bin is formed of a three dimensionally chill formed structural layer composed of PET fiber to which is mated, preferably by needle tacking, an inner carpet layer also composed of PET fiber providing two stage noise, sound and vibration reduction. In a preferred embodiment, the inner PET fiber carpet layer is mated, preferably by needle tacking, to an outer structural moldable PET fiber substrate layer forming a two-stage sound, noise and vibration absorbing and isolating thermoformable blank that is chilled formed into a sound absorbing glovebox bin of one piece flip open construction that is lighter in weight and which has reduced sound and noise generation and transmission compared to conventional hard plastic gloveboxes.

A trim component for attachment to a vehicle seat includes a first portion and a second portion. The first portion is disposed on a first side of the trim component and defines a first knit. The second portion is disposed on a second side of the trim component and defines a second knit distinct from the first knit. The first and second portions are integrally knitted. The trim component is configured to be installed on or more support members of the seat. The first side is configured to face the support member. The second portion is configured communicate with an occupant of the seat. In various aspects, the first portion includes a first yarn and the second portion includes a second yarn that is distinct from the first yarn with respect to one or more of density, thickness, and material. In various aspects, the first yarn is a heat-activated yarn.

Methods for ultrasonic welding of thermoplastic polymer workpieces and assemblies made therefrom are provided. The method may comprise disposing a first region of a first thermoplastic polymer workpiece and a second region of a second thermoplastic polymer workpiece between an ultrasonic horn and an anvil of an ultrasonic welding device. The first workpiece has a preformed deformation and at least one of the first and/or second workpieces has an adhesive precursor applied thereto. The ultrasonic horn or anvil seats within the preformed deformation. Ultrasonic energy is applied from the ultrasonic horn to create a weld nugget between the first and second workpieces. The assembly thus formed has a green strength sufficient to be further processed immediately. The methods provide a robust weld joint with controlled adhesive bondline thickness.