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 method for producing an insulation material is described herein. The method includes mixing cellulose reinforcement fibers with thermoplastic binder fibers to form a mixture. In addition, the method includes applying heat to the mixture to melt the thermoplastic binder fibers such that the thermoplastic binder fibers bind the cellulose reinforcement fibers together to form a batt. The thermoplastic binder fibers make up about 0.5% to about 25% by weight of the batt. Furthermore, the method includes slicing the batt along a horizontal plane to form a first pad having a first thickness and a second pad having a second thickness. Each of the first and second thicknesses is greater than or equal to about 1/16 of an inch.

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 repulpable insulation material includes a batt formed of a mixture of thermoplastic binder fibers and cellulose fibers bound together by the thermoplastic binder fibers. The thermoplastic binder fibers make up about 0.5% to 25% by weight of the batt. The repulpable insulation material have a weight within a range from 1000 GSM to 1600 GSM. Subjecting the repulpable insulation material to a repulpability test produces greater than 85% fiber yield.

A method of forming a shipping container includes mixing paper fibers with a binder fiber to form a mixture; disposing the mixture onto a surface to form a layer of the mixture; applying heat to form a paper fiber batt from the mixture having a fixed width and fixed length; and inserting the paper fiber batt within an interior of a corrugated box.

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.

Disclosed is a method of and an apparatus for manufacturing a sheet molding compound (SMC), the method including: continuously supplying a bottom film; applying a bottom resin on the bottom film; continuously supplying a carbon fiber; spreading the carbon fiber for widening; cutting the carbon fiber into a predetermined length and distributing the cut carbon fiber on the bottom resin; continuously supplying a top film; applying a top resin on a lower surface of the top film; and laminating the bottom film and the top film such that the carbon fiber is impregnated with the resin. According to the present invention, a large tow carbon fiber is widened by spreading to improve resin impregnability, thereby being capable of manufacturing a high quality SMC having improved physical properties with low cost.

A repulpable insulation material includes a batt formed of a mixture of thermoplastic binder fibers and cellulose fibers bound together by the thermoplastic binder fibers. The thermoplastic binder fibers make up about 0.5% to 25% by weight of the batt. The repulpable insulation material have a weight within a range from 1000 GSM to 1600 GSM. Subjecting the repulpable insulation material to a repulpability test produces greater than 85% fiber yield.

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.