Patent ID: 7914635
Filing Date: 2011-03-29
Classification: D04H,Y10T

Abstract:
1. A method for producing a unitary, fiber-containing composite, the method comprising the steps of: (a) providing a plurality of first binder fibers, a plurality of second binder fibers, a plurality of third binder fibers, and a plurality of bast fibers; (b) blending the pluralities of first binder fibers, second binder fibers, third binder fibers, and bast fibers to produce a fiber blend; (c) projecting the fiber blend onto a moving belt such that a unitary, fiber-containing composite is formed, the unitary, fiber-containing composite comprising (i) a first region comprising a plurality of the first binder fibers and a plurality of the bast fibers, (ii) a second region disposed above the first region, the second region comprising a plurality of the second binder fibers and a plurality of the bast fibers, (iii) a third region disposed above the second region, the third region comprising a plurality of the third binder fibers and a plurality of the bast fibers (iv) a first transitional region disposed between the first region and the second region, the first transitional region comprising concentrations of the first binder fiber, the second binder fiber, and the bast fiber, the concentration of the first binder fiber in the first transitional region being greatest proximate to the first region and least proximate to the second region, and the concentration of the second binder fiber in the first transitional region being greatest proximate to the second region and least proximate to the first region, (v) and a second transitional region disposed between the second region and the third region, the second transitional region comprising concentrations of the second binder fiber, the bast fiber, and the third binder fiber, the concentration of the second binder fiber in the second transitional region being greatest proximate to the second region and least proximate to the third region, and the concentration of the third binder fiber in the second transitional region being greatest proximate to the third region and least proximate to the second region, and (d) providing a scrim on a surface of the composite adjacent to the first region.