Patent ID: 7651964

Claim:
A unitary, fiber-containing composite comprising: (a) a first region comprising a plurality of first thermoplastic binder fibers and a plurality of bast fibers; (b) a second region disposed above the first region, the second region comprising a plurality of second thermoplastic binder fibers, and a plurality of bast fibers; and (c) 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, wherein the first binder fibers have a first linear density, the second binder fibers have a second linear density, and the second linear density is greater than the first linear density.