A process for forming a moldable, uncured nonwoven composite containing forming a structural nonwoven layer, at least partially impregnating the structural nonwoven layer with an uncured, water-based thermosetting resin having a cure temperature of at least about 160° C., and at least partially drying the uncured, wet nonwoven composite such that the temperature at the inner plane is less than about 130° C. forming an moldable, uncured composite. The structural nonwoven layer contains a plurality of bi-component binder fibers and a plurality of reinforcing fibers, the bi-component fibers containing a core and a sheath. The core contains a polymer having a melting temperature of at least about 180° C. and the sheath contains a polymer having a melting temperature less than about 180 ° C. A process for forming a molded, cured composite containing forming a structural nonwoven layer and a molded cured nonwoven composite are also disclosed.

A process for forming a moldable, uncured nonwoven composite containing forming a structural nonwoven layer, at least partially impregnating the structural nonwoven layer with an uncured, water-based thermosetting resin having a cure temperature of at least about 160° C., and at least partially drying the uncured, wet nonwoven composite. The structural nonwoven layer contains a plurality of binder fibers and a plurality of reinforcing fibers which are cellulosic fibers. Heat and pressure are applied to the moldable, uncured composite to a temperature of at least about 160° C. at least partially melting the binder fibers, curing the water-based thermosetting resin, and bonding at least a portion of the reinforcing fibers to other reinforcing fibers forming the molded, cured composite. The reinforcing fibers react with and form covalent bonds with the thermosetting resin.

An industrial mat that has a support core configured and arranged to support other components of the mat; and upper and lower layers that provide upper and lower surfaces of the mat and that protect the support core. The support core includes a frame of longitudinal side members, end members and cross members each of which is made of steel or a thermosetting plastic material. The frame can include wood, plastic or elastomeric internal members or materials to fill internal open areas of the frame, with the upper and lower layers and the sides and ends of the frame retaining the internal members or materials therein. The mat preferably includes lifting elements of D-shaped rings, O-shaped rings, chains, or cables attached to the upper or lower layer or the support core to provide certified overhead lifting of the mat for installation and reclamation thereof.

An industrial mat that has a support core configured and arranged to support other components of the mat; and upper and lower layers that provide upper and lower surfaces of the mat and that protect the support core. The support core includes a frame of longitudinal side members, end members and cross members each of which is made of steel or a thermosetting plastic material. The frame can include wood, plastic or elastomeric internal members or materials to fill internal open areas of the frame, with the upper and lower layers and the sides and ends of the frame retaining the internal members or materials therein. The mat preferably includes lifting elements of D-shaped rings, O-shaped rings, chains, or cables attached to the upper or lower layer or the support core to provide certified overhead lifting of the mat for installation and reclamation thereof.

A crane mat having first and second side beams or boards; a core structure made of pine or other softwoods, eucalyptus, solid plastic or elastomeric members, or hollow thermoplastic, thermosetting plastic or elastomeric members that optionally include a filler or internal reinforcing structure; external components including an upper and/or lower layers of one or more elongated members to protect the core structure, and a plurality of joining members that attach the outer side members to the core structure. Another crane mat can be made of just the solid plastic or elastomeric members, or hollow thermoplastic, thermosetting plastic or elastomeric members that each include a plurality of spaced lateral apertures passing therethrough; and joining members that include a rod that passes through the aligned lateral apertures to hold the members together in the mat. These crane mats may also include lifting elements of the types described herein.

A concrete curing blanket includes an absorbent sheet having a wicking layer, super absorbent materials, and a tissue layer, which are laminated together to form the absorbent sheet. The absorbent sheet is sized for being spread over a curing concrete slab. A vapor barrier is bonded to the tissue layer of the absorbent sheet to inhibit evaporation from the concrete curing blanket, and includes a plurality of perforations.

A concrete curing blanket includes an absorbent sheet having a wicking layer, super absorbent materials, and a tissue layer, which are laminated together to form the absorbent sheet. The absorbent sheet is sized for being spread over a curing concrete slab. A vapor barrier is bonded to the tissue layer of the absorbent sheet to inhibit evaporation from the concrete curing blanket, and includes a plurality of perforations.

The present invention is directed to an environmentally friendly composite structure and storage article fabricated therefrom. The composite structure includes a fiber-containing layer, such as a fiberboard layer or other layer having fibers from natural and/or synthetic sources, and a ground calcium carbonate-containing layer covering the fiber-containing layer. The ground calcium carbonate-containing layer is substantially continuously bonded to the fiber-containing layer along the surface of the fiber-containing layer. The fiber-containing layer and ground calcium carbonate-containing layer can be shaped, sized and manufactured such that the composite structure formed therefrom is capable of being shaped to form the storage article. The composite structure has advantages in that it has a high degree of pliability and flexibility that is increased over the pliability of the fiber-containing layer alone, which renders it highly attractive to consumers. The composite structure further has tensile strength and other characteristics that allow it to be readily machined into desired storage article forms, such as box and carton forms.

Described is a method of making a densified fiber batt that includes the steps of: a) providing a fiber batt with a first plurality of fibers having a first melting point and a second plurality of fibers having a second melting point different from the first melting point; and b) subjecting the fiber batt to heat and pressure in a static press, thereby forming a densified fiber batt having a first surface and an opposed second surface.

A magnesium-oxide wall tile for use in a modular wall system includes a plurality of layers. The plurality of layers includes an inner core comprising magnesium-oxide and having a length and a height and a front face and a back face. plurality of layers also includes a thermofoil layer disposed over at least one face of the inner core.