Unexpectedly unique and environmentally friendly composite material structures, storage articles fabricated therefrom, and related methods. The composite structure includes at least one or more fiber-containing layers, such as fiberboard or other layers having fibers from natural and/or synthetic sources, and one or more mineral-containing layers. The mineral-containing layer(s) comprises a thermoplastic bonding agent fixing the mineral particles in place. The fiber-containing layer(s) and mineral-containing layer(s) can be shaped, sized, and manufactured such that the composite structure formed therefrom is capable of being machined to form the storage article. The composite structure can be repulped and recycled without the use of dispersions, emulsions, or aqueous solutions. Further, the composite reduces layer mass requirements for heat seal, barrier, and fiber adhesion compared to polymer layers. The composite structure further has tensile strength and other structural characteristics that allow it to be readily machined into desired storage article forms.

A plank has a first portion with at least three layers. The first layer is of a plant material, and has an inner surface that includes a nonwoven fabric or a fiberglass mesh. The second layer is of an adhesive paper material that includes a macromolecular glue where the macromolecular glue is 50-55% melamine, 35-40% plasticizer, and 3-5% formaldehyde. The third layer is one of bamboo, wood, or paper. The plank has a second portion, which may be of a plastic composite base material or a magnesium oxide composite base material. When the second portion is of a plastic composite material, the first portion is fused to the second portion by cold pressing or a polyurethane reactive adhesive. When the second material is of a magnesium oxide composite base material, the first portion is thermally pressed to the second portion by cold pressing, hot pressing or a polyurethane reactive adhesive.

A plank has a first portion with at least three layers. The first layer is of a plant material, and has an inner surface that includes a nonwoven fabric or a fiberglass mesh. The second layer is of an adhesive paper material that includes a macromolecular glue where the macromolecular glue is 50-55% melamine, 35-40% plasticizer, and 3-5% formaldehyde. The third layer is one of bamboo, wood, or paper. The plank has a second portion, which may be of a plastic composite base material or a magnesium oxide composite base material. When the second portion is of a plastic composite material, the first portion is fused to the second portion by cold pressing or a polyurethane reactive adhesive. When the second material is of a magnesium oxide composite base material, the first portion is thermally pressed to the second portion by cold pressing, hot pressing or a polyurethane reactive adhesive.

Embodiments herein relate to a composite material including about 10 to 80 wt. % of a polymer phase, the polymer phase comprising a thermoplastic polymer with a density of less than about 1.9 g-m-2; and about 20 to 90 wt. % of a dispersed mixed particulate phase, the dispersed mixed particulate phase comprising a mixed particulate and about 0.005 to 8 wt. % of a coating of at least one interfacial modifier. The mixed particulate including a portion of a reinforcing fiber and a portion of a particle. The composite material having a Young's modulus of greater than 700 MPa. In various embodiments, structural building components made from the composite are included as well as additive manufacturing components made from the composite. Other embodiments are also included herein.

Embodiments herein relate to a composite material including about 10 to 80 wt. % of a polymer phase, the polymer phase comprising a thermoplastic polymer with a density of less than about 1.9 g-m-2; and about 20 to 90 wt. % of a dispersed mixed particulate phase, the dispersed mixed particulate phase comprising a mixed particulate and about 0.005 to 8 wt. % of a coating of at least one interfacial modifier. The mixed particulate including a portion of a reinforcing fiber and a portion of a particle. The composite material having a Young's modulus of greater than 700 MPa. In various embodiments, structural building components made from the composite are included as well as additive manufacturing components made from the composite. Other embodiments are also included herein.

A method of extrusion additive manufacturing for veneer applications may include, but is not limited to, loading material into an extruder, generating a mixture from the material, and fabricating the veneer product. Fabricating the veneer product may include depositing a first portion of the mixture on a working surface of the extruder, actuating the working surface, and depositing an additional portion of the mixture on the working surface of the extruder proximate to the first position of the mixture deposited on the working surface. Where the first portion of the mixture and the additional portion of the mixture form a first layer of the veneer product, fabricating the veneer product may include actuating a nozzle of the extruder and depositing an additional layer of the mixture on the first layer of the veneer product. The material may include wood product and a binder.

Embossed fibrous structures that exhibit a Dry Burst of greater than 270 g as measured according to the Dry Burst Test Method and more particularly to embossed fibrous structures that exhibit a Dry Burst of greater than 270 g as measured according to the Dry Burst Test Method and a Total Dry Tensile of less than 2375 g/76.2 mm and/or a Geometric Mean Total Dry Tensile of less than 1130 g/76.2 mm as measured according to the Tensile Strength Test Method are provided.

A method to provide a floor covering, including the steps of: providing a sheet vinyl; providing a PVC intermediate including at least a first layer of PVC material and at least a first reinforcing sheet, the first layer of PVC material providing the upper side of the PVC intermediate. The method also includes adhering the sheet vinyl to the PVC intermediate by laminating the lower side of the sheet vinyl to the upper side of the PVC intermediate.

A method to provide a floor covering, including the steps of: providing a sheet vinyl; providing a PVC intermediate including at least a first layer of PVC material and at least a first reinforcing sheet, the first layer of PVC material providing the upper side of the PVC intermediate. The method also includes adhering the sheet vinyl to the PVC intermediate by laminating the lower side of the sheet vinyl to the upper side of the PVC intermediate.

In order to provide a method of molding plant-based material to mold three-dimensional shape of cross section for relatively long plant-based material while maintaining the continuity of original cell/tissue of the plant-based material by means of simple equipment and process, we obtained a long plant-based material of high density and high strength by continuously giving compressing/drawing deformation to the component tissue of the plant-based material toward the center direction while extruding the plant-based material via the extruding die having a prescribed extrusion ratio and die angle for a relatively long plant-based material long in the fiber direction.