The invention relates to systems and techniques for manufacturing articles containing cellulosic material, a coupling agent, and a binder resin, and related processes of making and using the cellulosic articles. In particularly exemplary embodiments, the manufactured articles are door skins, sometimes known as door facings, and doors made from the door skins. The article contains a lipophilic cellulosic material, a coupling agent, and a binder. The coupling agent is believed to increase the hydrophilicity (wetability) of the lipophilic cellulosic material.

A process for forming a nonwoven composite begins with forming a first nonwoven from a plurality of primary fibers and optionally binder fibers. A second nonwoven layer is formed from a plurality of bulking fibers and binder fibers. A thermoplastic elastomeric film is placed between the two nonwoven layers, the film containing a thermoplastic elastomeric polymer having an elongation at break greater than 300% and a max softening point (thermomechanical analysis end point) between 150 C. and 200 C. as tested according to ASTM E2347-04. The layers are needled together creating a plurality of holes in the thermoplastic elastomeric layer and moving a portion of the primary fibers from the first nonwoven layer into the second nonwoven layer. The needled stacked layers are heated to alter the median size of the holes in the thermoplastic elastomeric film forming the nonwoven composite.

The invention relates to systems and techniques for manufacturing articles containing cellulosic material, a tackifier, and a binder, and related processes of making and using the cellulosic articles. In particularly exemplary embodiments, the manufactured articles are door skins, sometimes known as door facings, and doors made from the door skins. The article contains a lipophilic cellulosic material, a tackifier, and a binder.

To ease and improve the production of objects, a method is described for producing an object (60) comprising a structural core (10) and an outer coating of polymeric material (52), comprising the steps of (i) coating with polymeric material (50) a lamina (10), wherein the lamina comprises a surface exhibiting macroscopic discontinuities (32) configured so that the polymeric material grips to them in order to form a multilayered piece; (ii) removing parts from the multilayer piece to obtain a contour corresponding to the object, the contour comprising an edge (B) along which a margin of the lamina remains uncovered by the polymeric material.

Provided is a thermoplastic resin film having at least one of film surfaces being excellent in printability, having sufficiently low internal haze, and exhibiting a favorable matte appearance. A thermoplastic resin film according to the present invention composed of a thermoplastic resin composition (C) including at least one kind of a thermoplastic resin (R) and fine particles (P) having a volume average particle diameter of 0.5 to 15 m and a refractive index different from that of the thermoplastic resin (R) by 0.02 or more.

At least one of film surfaces satisfies formulas (1) and (2).

G.sub.L60(1),

G.sub.L35G.sub.HG.sub.L10(2)

(In the formulas (1) and (2), G.sub.L is 60 gloss (%) at 20 C., G.sub.H is 60 gloss (%) when the thermoplastic resin film is heated at a temperature 10 C. higher than a glass transition temperature of the thermoplastic resin composition (C) for 30 minutes, then cooled to 20 C.)

Provided is a shaped article including a hardcoat layer, where the hardcoat layer has surface hardness, flexibility, and heat resistance at high levels and offers excellent workability. The shaped article according to the present invention is a shaped article including a hardcoat layer, a substrate layer, and a thermoplastic resin layer and having a curved shape. The hardcoat layer defines an outermost surface of the shaped article. The hardcoat layer includes a cure product of a curable composition. The curable composition includes a cationically curable silicone resin and a leveling agent. The cationically curable silicone resin includes a silsesquioxane unit. The cationically curable silicone resin includes an epoxy-containing monomeric unit in a proportion of 50 mole percent or more of the totality of all monomeric units and has a number-average molecular weight of 1000 to 3000.

The present invention relates to cleansing articles comprising first and second members forming the first and second outer surface of the article respectively, where the coefficient of friction and/or permeability of the members are different. In certain embodiments the first member comprises a plurality of polymeric protuberances and the second member comprises a plurality of hollow projections.

A wood adhesive, a method for adhering wood materials using the same, and a composite wood structure using the same are disclosed. The wood adhesive comprises a first agent and a second agent, wherein the first agent comprises sodium carboxymethyl cellulose having a molecular weight from about 15,000 to about 500,000 and a degree of substitution from about 0.4 to about 2, and the second agent comprises polymeric quaternary amine.

The invention relates to systems and techniques for manufacturing articles containing cellulosic material, a coupling agent, and a binder resin, and related processes of making and using the cellulosic articles. In particularly exemplary embodiments, the manufactured articles are door skins, sometimes known as door facings, and doors made from the door skins. The article contains a lipophilic cellulosic material, a coupling agent, and a binder. The coupling agent is believed to increase the hydrophilicity (wetability) of the lipophilic cellulosic material.

A process for forming a nonwoven composite begins with forming a first nonwoven from a plurality of primary fibers and optionally binder fibers. A second nonwoven layer is formed from a plurality of bulking fibers and binder fibers. A thermoplastic elastomeric film is placed between the two nonwoven layers, the film containing a thermoplastic elastomeric polymer having an elongation at break greater than 300% and a max softening point (thermomechanical analysis end point) between 150 C. and 200 C. as tested according to ASTM E2347-04. The layers are needled together creating a plurality of holes in the thermoplastic elastomeric layer and moving a portion of the primary fibers from the first nonwoven layer into the second nonwoven layer. The needled stacked layers are heated to alter the median size of the holes in the thermoplastic elastomeric film forming the nonwoven composite.