A form for a thin reinforced composite material includes a plurality of separate linear fiber strips, each having a rectangular cross section composed of reinforcement fibers. The linear fiber strips laid out in a two-dimensional base layer defining a shape of the form. A first successive layer formed with the plurality of separate linear fiber strips contacting the base layer, the linear fiber strips laid out in the first successive layer interspersed from the separate linear fiber strips in the two-dimensional base layer. A method of forming the form includes arranging the plurality of separate linear fiber strips on a substrate and tacking the plurality of separate linear fiber strips to the substrate with a plurality of stitches. A method of forming a unitary reinforced composite component from the form is further provided. The resulting component having high strength and light weight and being efficient to manufacture.

A panel including at least a substrate of thermoplastic material and a top layer with a printed decor and a translucent or transparent wear layer. The substrate has a thickness larger than one half of the thickness of the entire panel, and the substrate at least includes two layers, where the two layers each include thermoplastic material. A first one of the two layers further includes at least 60 percent by weight of filler materials and a second one of the two layers includes less fillers or is not filled, and is situated above the first one of the two layers.

In a composite sheet manufacturing device, a second roller having a plurality of first projections and a third roller are disposed so as to be adjacent to a first roller having multiple recessed areas. The outer diameters of the first and third rollers are the same size. The third roller is joined to the first roller with a first gear pair therebetween, so as to rotate at the same rotation frequency as that of the first roller. A first sheet that is fed in between the first roller and the second roller is shaped by being pushed into the recessed areas of the first roller by the first projections of the second roller. A second sheet is then superimposed onto the first sheet and is passed through the space between the first roller and the third roller, and the first and second sheets are thereby bonded to each other.

An air/gas filter medium is comprised of a substantially homogeneous core layer of feather down clusters held together by a binder to form a 3-dimensional interconnected filament structure throughout the core. The filament structure forms air pocket and connect and trap the feather down clusters which form minute air pockets between its filaments and hairs in which undesirable substances from an air/gas flow therethrough are captured. An air permeable scrim sheet is retained on a surface of the down cluster core. The down cluster core is compressed to a predetermined density to modify the average size of said minute air pockets to trap known undesirable substances from the air/gas flow.

A polymeric composite derived from a reclaimed polymeric material. The polymeric composite in particulate form can be thermally compressed into panels and other embodiments that require a component that possesses sufficient mechanical strength and moisture resistance. In certain embodiments, the panel may be utilized as one layer in a multilayered article.

A panel including at least a substrate of thermoplastic material and a top layer with a printed decor and a translucent or transparent wear layer. The substrate includes three layers, including a lowermost layer, a central layer and an uppermost layer, all made from thermoplastic material, where the thermoplastic material of the central layer is more rigid than the thermoplastic material of the lower most layer and the uppermost layer.

In a composite sheet manufacturing device, a second roller having a plurality of first projections and a third roller are disposed so as to be adjacent to a first roller having multiple recessed areas. The outer diameters of the first and third rollers are the same size. The third roller is joined to the first roller with a first gear pair therebetween, so as to rotate at the same rotation frequency as that of the first roller. A first sheet that is fed in between the first roller and the second roller is shaped by being pushed into the recessed areas of the first roller by the first projections of the second roller. A second sheet is then superimposed onto the first sheet and is passed through the space between the first roller and the third roller, and the first and second sheets are thereby bonded to each other.

A method of manufacturing a wood-based board. The method includes applying at least one first fibre mat including a first mix comprising lignocellulosic particles and a binder on a carrier, applying a second fibre mat including a second mix including cellulosic particles and a binder on said at least one first fibre mat, and pressing said at least one first fibre mat into a base layer and the second fibre mat into a surface layer simultaneously, thereby forming a wood-based board. Also, to such a wood-based board.

A sheetlike composite material including at least one layer A of a nonwoven thermoplastic fiber web or a thermoplastic film, and at least two unidirectional oriented-fiber layers B and B, the layers B and B having a bidirectional fiber orientation. The layers are not only needled but also stitched to one another.

A panel for forming a floor covering, where this panel includes a substrate including at least a layer of thermoplastic material, where the panel, above the layer, comprises at least also a printed decor and a translucent or transparent wear layer. The layer also includes at least individual fibers having a length greater than 1 millimeter, where the individual fibers are loose and freely distributed within the layer of thermoplastic material.