A reinforcing fiber composite material includes at least a matrix resin and discontinuous reinforcing fibers which include discontinuous reinforcing fiber aggregates, wherein the discontinuous reinforcing fibers include at least 5 wt % of discontinuous reinforcing fiber aggregates (A) in each of which a most widened section, where the width of the discontinuous reinforcing fiber aggregate in a direction intersecting the alignment direction of the discontinuous reinforcing fibers is made greatest when the discontinuous reinforcing fiber aggregate is two-dimensionally projected, is present at a position excluding both ends of the discontinuous reinforcing fiber aggregate, and the aspect ratio (width of the discontinuous reinforcing fiber aggregate/thickness of the discontinuous reinforcing fiber aggregate) of the most widened section is 1.3 times or more the aspect ratio of at least one of the ends of the discontinuous reinforcing fiber aggregate.

A manufacturing method of an SMC of the present invention comprises (i) forming chopped carbon fiber bundles by chopping a continuous carbon fiber bundle having a filament number of NK with a rotary cutter, (ii) fragmentation-processing the chopped carbon fiber bundles by using a fragmentation-processing apparatus comprising a rotating body, (iii) forming a carbon fiber mat by depositing the fragmentation-processed chopped carbon fiber bundles on a carrier film traveling below the rotary cutter, and (iv) impregnating the carbon fiber mat with a thermosetting resin composition, wherein N is 20 or more, and the fragmentation-processing apparatus comprises a first pin roller and a second pin roller which are disposed side by side, each having a rotation axis parallel to a rotation axis direction of the rotary cutter.

A fiber-reinforced fabric, composite materials formed from such fabrics, and methods of making the fiber-reinforced fabric or composite materials, are provided. The fabrics and composite materials demonstrate improved fatigue performance relative to conventional fiber-reinforced fabrics.

A repulpable insulated container assembly having a container formed of paper such as corrugated cardboard or varying paper materials and defining an interior; and a repulpable insert placed within the interior of the container and formed of a first paper layer; and a paper fiber pad coupled to the first paper layer.

A chopped roving thermoplastic composite sheet includes a web or mesh of chopped rovings and a thermoplastic resin that fully saturates the web or mesh of chopped rovings. The web or mesh of chopped rovings is not mechanically bonded and does not include a binder that bonds or adheres the chopped rovings together other than thermoplastic resin. As such, the thermoplastic resin and the web or mesh of chopped rovings are able to flow and conform to a mold or cavity when the chopped roving thermoplastic composite sheet is pressed within the mold or cavity and when the chopped roving thermoplastic composite sheet is heated to above the melting temperature of the thermoplastic resin.

A method and apparatus for manufacturing a filler for a composite structure. The apparatus may comprise a filler. The filler may comprise a fiber matrix that is uniform in all directions. The fiber matrix may comprise a first plurality of discontinuous filaments and a second plurality of discontinuous filaments. Each filament of the first plurality of discontinuous filaments may be comprised of a stiffening material. Each filament of the second plurality of discontinuous filaments may be comprised of a binding material. Discontinuous filaments of both the first plurality of discontinuous filaments and the second plurality of discontinuous filaments may be randomly oriented and entangled with each other.

A repulpable insulated container assembly having a container formed of paper such as corrugated cardboard or varying paper materials and defining an interior; and a repulpable insert placed within the interior of the container and formed of a first paper layer; and a paper fiber pad coupled to the first paper layer.

There are provided a sheet material pressing device, a sheet material pressing method, and a pressing roller. A sheet material pressing device includes: a pressing roller having a plurality of free rollers for pressing a sheet material in which resin and fibers are mixed, and a free roller support unit disposes the plurality of free rollers in an annular shape and fixes and supports the plurality of free rollers so as to rotate freely; a driving control unit that rotates the free roller support unit in a first rotation direction in order to revolve the plurality of free rollers; and a sheet material conveying unit on which the sheet material is placed and conveyed. The first rotation direction is a direction in which a moving direction of the free roller at a pressing position of the sheet material is a direction opposite to a conveying direction of the sheet material.

A repulpable insulated container assembly having a container formed of paper such as corrugated cardboard or varying paper materials and defining an interior; and a repulpable insert placed within the interior of the container and formed of a first paper layer; and a paper fiber pad coupled to the first paper layer.

A repulpable insulated container assembly having a container formed of paper such as corrugated cardboard or varying paper materials and defining an interior; and a repulpable insert placed within the interior of the container and formed of a first paper layer; and a paper fiber pad coupled to the first paper layer.