Methods of producing particles of fiber and resin from fiber-resin composite materials are disclosed. The particles may be combined with a resin system and optionally combined with fillers, binders or reinforcements to produce new cured solid composite products.

A 3-dimensional high-strength fiber composite component having isotropic fiber distribution, comprising 25 to 70 wt % of high-strength, high-modulus fibers, up to 5 wt % of binding fibers, and 25 to 70 wt % of thermosetting or thermoplastic matrix. The invention further relates to a method for producing same, comprising the following steps: preparing the fibers by opening the fibers by releasing the fibers from fiber bundles, bales, or textile structures; sucking and/or blowing the opened fibers onto a three-dimensional, air-permeable tool half having the contour of this side of the component in an interactively controlled manner; pre-solidifying the obtained fiber molding in the flock box; transferring the fiber molding onto a pressing tool in the form of the contour of the air-permeable tool half of the component; bringing into contact with at least one liquid plastic; and solidifying the fiber molding by pressing in order to form a component.

A 3-dimensional high-strength fiber composite component having isotropic fiber distribution, comprising 25 to 70 wt % of high-strength, high-modulus fibers, up to 5 wt % of binding fibers, and 25 to 70 wt % of thermosetting or thermoplastic matrix. The invention further relates to a method for producing same, comprising the following steps: preparing the fibers by opening the fibers by releasing the fibers from fiber bundles, bales, or textile structures; sucking and/or blowing the opened fibers onto a three-dimensional, air-permeable tool half having the contour of this side of the component in an interactively controlled manner; pre-solidifying the obtained fiber molding in the flock box; transferring the fiber molding onto a pressing tool in the form of the contour of the air-permeable tool half of the component; bringing into contact with at least one liquid plastic; and solidifying the fiber molding by pressing in order to form a component.

A composite material containing reinforcing fibers A and a matrix resin, the reinforcing fibers A being discontinuous fibers having a fiber length of at least 5 mm and containing reinforcing fibers A1 having a bundle width of less than 0.3 mm and a reinforcing fiber bundle A2 having a fiber width of 0.3-3.0 mm, inclusive, wherein the coefficient of variation CVi.sub.A2 of Vfi.sub.A2 is 35% or less in at least a minimum bundle width zone (i=1) and a maximum bundle width zone (i=n) when the reinforcing fiber bundle A2 is divided into a pre-set plurality of bundle width zones (total number of bundle width zones n≥3) and the volume ratio of the reinforcing fiber bundle A2 in each bundle width zone is Vfi.sub.A2. Also, a method for producing a molded article which uses the composite material.

A composite material containing reinforcing fibers A and a matrix resin, the reinforcing fibers A being discontinuous fibers having a fiber length of at least 5 mm and containing reinforcing fibers A1 having a bundle width of less than 0.3 mm and a reinforcing fiber bundle A2 having a fiber width of 0.3-3.0 mm, inclusive, wherein the coefficient of variation CVi.sub.A2 of Vfi.sub.A2 is 35% or less in at least a minimum bundle width zone (i=1) and a maximum bundle width zone (i=n) when the reinforcing fiber bundle A2 is divided into a pre-set plurality of bundle width zones (total number of bundle width zones n≥3) and the volume ratio of the reinforcing fiber bundle A2 in each bundle width zone is Vfi.sub.A2. Also, a method for producing a molded article which uses the composite material.

A three-dimensional object comprises stacked substrate layers infiltrated by a hardened material. Each substrate layer is a sheet-like structure that comprises fibers held together by a sodium silicate binder. The substrate layer material may be non-woven or woven. The substrate layer may be a non-woven fiber veil bound by a sodium silicate binder. The fibers may optionally include carbon fibers, ceramic fibers, polymer fibers, glass fibers, metal fibers, or a combination thereof.

Expandable substrates, which are referred to as blanks, are created by compressing thermobonded nonwovens after heating the binder material above its melting temperature, and then cooling the compressed nonwovens so that the binder material hardens and holds the fibers of the nonwoven together in a compressed configuration with stored kinetic energy. A mold for the component to be manufactured can be partially filled with a number of boards (or blanks) in a stacked, vertically, adjacent or even random orientation. Upon application of heat to the boards or blanks or parts in the mold, the binder material is melted so as to allow the nonwoven material to expand in one or more directions, and thereby fill all or part of the mold. Upon cooling, the binder material again hardens, and the molded component is retrieved from the mold.

Expandable substrates, which are referred to as blanks, are created by compressing thermobonded nonwovens after heating the binder material above its melting temperature, and then cooling the compressed nonwovens so that the binder material hardens and holds the fibers of the nonwoven together in a compressed configuration with stored kinetic energy. A mold for the component to be manufactured can be partially filled with a number of boards (or blanks) in a stacked, vertically, adjacent or even random orientation. Upon application of heat to the boards or blanks or parts in the mold, the binder material is melted so as to allow the nonwoven material to expand in one or more directions, and thereby fill all or part of the mold. Upon cooling, the binder material again hardens, and the molded component is retrieved from the mold.

A fiber mat includes a unitary assembly of fibers including at least a first set of fibers and at least a first binder comprising an organic resin, wherein the unitary assembly of fibers includes a minority portion and a majority portion different than the minority portion, wherein the fiber mat provides at least a 5% increase in tear when placed in a bituminous roofing product compared to an equivalent bituminous roofing product made with a fiber mat of equivalent weight containing a homogenous mat structure.

A fiber mat includes a unitary assembly of fibers including at least a first set of fibers and at least a first binder comprising an organic resin, wherein the unitary assembly of fibers includes a minority portion and a majority portion different than the minority portion, wherein the fiber mat provides at least a 5% increase in tear when placed in a bituminous roofing product compared to an equivalent bituminous roofing product made with a fiber mat of equivalent weight containing a homogenous mat structure.