A method of making a golf club head includes a preparation step, a weaving step, and a forming step. In the preparation step, a pattern of a golf club head having a plurality of parts is drawn using a computer. In the weaving step, a plurality of fiber bundles are woven to form a rough blank simulating the pattern of the golf club head drawn by the computer. The rough blank has a plurality of portions corresponding to the parts of the golf club head. In the forming step, the rough blank is placed in a mold, after which applying one of heat and energy to the mold is performed to form the golf club head having an uneven thickness.

A process is provided for thermal molding an article with at least one layer of thermoplastic fibers that are non-woven and uni-directionally oriented in combination with at least one layer of reinforcing fibers. The reinforcing fibers including glass, carbon, nature based, and combinations thereof; alone or mixed with chopped thermoplastic fibers. Upon subjecting the layers to sufficient heat to thermally bond in the presence of non-oriented filler fibers, thermoplastic fiber fusion encapsulates the filler fibers. The filler fibers impart physical properties to the resulting article and the residual unidirectional orientation of the thermoplastic melt imparts physical properties in the fiber direction to the article. By combining layers with varying orientations of uni-directional fibers relative to one another, the physical properties of the resulting article may be controlled and extended relative to conventional thermoplastic moldings. The uni-directional fibers may have discontinuities along the length of individual fibers.

A strengthened polyethylene tubular member, where the polyethylene tubular member has an outer surface, a circumference, a wall thickness, an area to be strengthened, and the outer surface of the polyethylene tubular member contains polyethylene. The strengthened polyethylene tubular member contains a fabric layer wrapped around the circumference of the tubular member at least two full rotations and covering the area to be strengthened. The fabric layer contains a plurality of interwoven tape elements with a base layer of a strain oriented olefin polymer disposed between covering layers of a heat fusible olefin polymer. The tape elements within the fabric layer are bonded together and the tape elements adjacent the tubular member are bonded to the tubular member.

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 making up about 0.5% to 25% by weight of the batt, the repulpable insulation material having a weight within a range from 1000 GSM to 1600 GSM, wherein subjecting the repulpable insulation material to a repulpability test produces greater than 85% fiber yield.

Unitary films and laminates thereof are provided having at least first and second film segments which extend adjacent one another and are permanently joined together. The first and second film segments are joined at an interface, wherein at the interface a tip of the second segment overlaps the first segment in the cross-direction of the film. The film has a thickness T at the tip of the second segment, and the second segment has a thickness t at a distance T in the cross direction from the tip of the second segment. The ratio T/t is suitably greater than about 3. The unitary films and laminates thereof are well suited, for example, for use as outer covers in personal care articles.

A fiber-modified interlayer includes a nonwoven fabric layer formed of continuous fibers, and discontinuous fibers attached to the nonwoven fabric, the fiber-modified interlayer is attached to at least one reinforcing layer of structural tows to form an interlayer-toughened reinforcing fabric, at least one layer of the interlayer-toughened reinforcing fabric is infused with a matrix material and cured to form a composite structure.

A system for producing rebar includes a pultruding machine configured to receive a flexible rebar preform. The flexible rebar preform includes at least one reinforcement filament, and at least one thermoplastic filament. The at least one reinforcement filament, and the at least one thermoplastic filament are arranged in a selected distribution across a cross-section of the preform. The pultruding machine includes a pulling apparatus, a rebar cutting apparatus, and a bending apparatus. The pultruding machine is configured to heat the flexible rebar preform to a first temperature. The first temperature is greater than or equal to a melt temperature of the thermoplastic filaments. The pulling apparatus is configured to pull the flexible rebar preform through a pultrusion die to form the rebar. The rebar cutting apparatus is configured to cut the rebar at a prespecified length. The bending apparatus is configured to bend the cut rebar to a prespecified bend geometry.

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.

A nonwoven trough and method of construction thereof are provided. The nonwoven trough includes at least one nonwoven wall formed from a mixture of bonded natural cellulosic fibers and thermoplastic fibers. The at least one nonwoven wall extends along a longitudinal axis and has a midsection and opposite end portions. The midsection has a base and a pair of walls extending upwardly from the base to provide the midsection with a generally U-shaped cross-section taken generally transversely to the longitudinal axis. At least one flange extends laterally from the at least one nonwoven wall, wherein the flange is configured for attachment to a vehicle member.

A nonwoven trough and method of construction thereof are provided. The nonwoven trough includes at least one nonwoven wall formed from a mixture of bonded natural cellulosic fibers and thermoplastic fibers. The at least one nonwoven wall extends along a longitudinal axis and has a midsection and opposite end portions. The midsection has a base and a pair of walls extending upwardly from the base to provide the midsection with a generally U-shaped cross-section taken generally transversely to the longitudinal axis. At least one flange extends laterally from the at least one nonwoven wall, wherein the flange is configured for attachment to a vehicle member.