MULTILAYER COMPOSITES, AND PROCESSES AND SYSTEMS FOR PREPARATION THEREOF

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and benefit from United States Patent Application

Serial No. 63/399,508 filed on August 19, 2022, which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

[0002] The present invention relates generally to layered non-woven composite products.

More specifically, the present invention relates to multilayer composites, and systems and processes for preparation thereof.

BACKGROUND

[0003] Traditional non-woven composites are manufactured using two or more fiber types and at least one resin type used to bond fibrous layers together to form a shaped article.

[0004] The most common composites are made with at least one fiber type consisting of a thermal melt polymer, such as polypropylene, and a least one or more non-melt fibers, usually consisting of either a polyester or a natural bast fiber. Other non-woven composites are made with at least two non-melt fibers, one being a natural fiber and the other being a polyester fiber. The use of a polyester fiber assists the process of needling the fibrous matrix into a sheet product that has enough supportive tensile strength allowing it to be infused with liquid thermal set resins, dried and then thermally processed into a shape. There are capabilities to combine these two different technologies together, but costs, such as machinery for traditional composites including, for example, expensive carding and cross lap machinery, as well as process capabilities, make it generally incompatible for commercial markets.

[0005] Traditional non-woven composites are also limited in the combinations of types of fiber material and resin that can be used therein. Using traditional techniques, a composite combining thermal melt fibers and thermal set resins may not be achieved in a commercially viable manner, nor could a composite with thermal melt and thermal set resins be made with multiple layers, such as for example, six layers or seven layers, where each layer consists of the same or different combinations of fiber types.

[0006] Additionally, traditional methods or processes to form composites do not allow the mismatching of fibers in each layer or the use of two different types of binding resins, such as thermal set resins and thermal melt resins. Owing to the unique properties of, for example, thermal set resins and thermal melt resins, the mismatching of said fibers would have advantages. Thermal melt composites have a better retention capability than thermal set composites, which may be beneficial for retention of, for example, screws. In contrast, thermal set composites have a much higher flexural modulus than thermal melts. The ability to combine and/or mismatch thermal set layers and thermal melt layers may therefore result in a composite with a balance between these properties, thus increasing product customization and utility.

[0007] Traditional non-woven composites are additionally limited in their capacity to receive recycled material. The ability to provide recycled material in a non-woven composite has significant positive environmental implications towards creating products that sequester carbon, products that are carbon free and/or products that are carbon neutral. The ability to sequester carbon in a first article of manufacture, then recover and recycle that back into the same or even different article of manufacture, while keeping all previous sequestered carbon locked within the original article, may have a benefit to improve air quality and reduce carbon emissions.

[0008] Therefore, a need exists for improved non-woven composites, and methods and systems for producing multilayer non-woven composites.

SUMMARY

[0009] The present disclosure provides non-woven multilayer composites, and systems and processes for the preparation thereof. The present disclosure recognizes that there are problems and limitations of traditional multilayer composites in respect to the products, as well as the systems and processes for their preparation.

[0010] An advantage of the present disclosure is the provision of multilayer composites, and systems and processes for the preparation thereof having improved characteristics over the existing technologies.

[0011] In an embodiment, the present disclosure relates to a process for preparing a non-woven multilayer composite, the process comprises the steps of: (a) providing a fiber blend comprising one or more fiber materials to a fiber scattering assembly, the fiber scattering assembly comprising a load cell that regulates the amount of a discharged fiber blend from the fiber scattering assembly; (b) laying a web of the discharged fiber blend from the fiber scattering assembly to form a composite layer; (c) delivering the composite layer to another of the fiber scattering assemblies as a previously laid composite layer; (d) repeating steps (a) to (c) one or more times using the previously laid composite layer(s) as a substrate for layering atop thereof each subsequent composite layer to provide a plurality of layers forming the non-woven multilayer composite, wherein the fiber blend used for each successive composite layer is the same or different than the fiber blend used in any of the previously laid composite layers. In certain embodiments, the fibers of the composite layer are substantially non-directional in arrangement.

[0012] In certain embodiments, each of the fiber scattering assemblies comprise a feed tower from which the fiber blend is supplied to the load cell, and optionally each of the fiber scattering assemblies is independently controllable.

[0013] In certain embodiments, the process disclosed herein further comprises in step (a), adjusting the amount of the fiber blend delivered to the load cell from the feed tower based on weight readings obtained by an input weigh scale.

[0014] In certain embodiments, the process disclosed herein further comprises adjusting the speed of steps (b) and/or (c) based on weight readings obtained by the input weigh scale.

[0015] In certain embodiments, in each repeated step (a) the fiber blend is provided to the respective fiber scattering assembly from an opposite side of the fiber scattering assembly than in the immediately preceding step (a).

[0016] In certain embodiments, the process further comprises between steps (b) and (c), a step of degassing the composite layer.

[0017] In certain embodiments, the step of degassing is separately and independently performed on each of the composite layers.

[0018] In certain embodiments, the process comprises in step (b) and the degassing step: (bl) laying the web of the discharged fiber blend onto a conveying belt; (b2) contacting the web of the discharged fiber blend with a degassing belt; and (b3) passing the web of the discharged fiber blend between the conveying belt and the degassing belt to provide the composite layer.

[0019] In certain embodiments, the degassing belt is angled relative to the conveying belt, such that the degassing belt is positioned closer to the conveying belt at a downstream end where the composite layer exits from between the conveying belt and the degassing belt, than at an upstream end where the discharged fiber blend begins passing between the conveying belt and the degassing belt. [0020] In certain embodiments, the degassing belt is at a different speed than the conveying belt. In certain embodiments, the degassing belt is at a slower speed than the conveying belt so as to drag and cause a regression on a top surface of the composite. In certain embodiments, the slower speed is sufficient to alter the orientation of fibers within the composite layer from a vertical orientation to a horizontal orientation

[0021] In certain embodiments, each of the layers of the plurality of layers of the non-woven multilayer composite has a surface density variation of less than 10% per layer. In certain embodiments, each of the layers of the plurality of layers of the non-woven multilayer composite has a surface density variation of less than 5% per layer. In certain embodiments, each of the layers of the plurality of layers of the non-woven multilayer composite has a surface density variation of less than 2% per layer.

[0022] In certain embodiments, the non-woven multilayer composite has an area density (gsm) that is within +/- 5% of a target density.

[0023] In certain embodiments, steps (a) to (c) are performed at least 3 times, at least 4 times, at least 5 times, at least 6 times, at least 7 times, or more. In certain embodiments, steps (a) to (c) are performed at least 6 times. In certain embodiments, steps (a) to (c) are performed at least 7 times.

[0024] In certain embodiments, a first composite layer and a final composite layer, each forming an exterior layer of the non-woven multilayer composite, are made from the same fiber blend.

[0025] In certain embodiments, each of one or more internal composite layers is made from a different fiber blend than the exterior layers. In certain embodiments, each composite layer is made from a different fiber blend. In certain embodiments, each composite layer is made from the same fiber blend.

[0026] In certain embodiments, the fiber blend in any cycle of steps (a) to (c) comprises at least a portion of a recycled trim waste, an end of life material, or any combination thereof to provide a layer comprising a recycled feed material to the non-woven multilayer composite.

[0027] In certain embodiments, steps (a) to (c) are performed one time with the recycled feed material.

[0028] In certain embodiments, the non-woven multilayer composite comprises a single recycled layer of the recycled feed material. In certain embodiments, the single recycled layer is a middle layer in the non-woven multilayer composite. [0029] In certain embodiments, steps (a) to (c) are performed two or more times with the recycled feed material.

[0030] In certain embodiments, the process further comprises after any cycle of steps (a) to (c), steps of: providing a recycled feed material to a recycler assembly, the recycled feed material comprising a recycled trim waste, an end of life material, or any combination thereof; and discharging a layer of the recycled feed material onto the previously laid composite layer(s) to provide a recycled layer to the nonwoven multilayer composite.

[0031] In certain embodiments, the recycled layer is a middle layer in the non-woven multilayer composite.

[0032] In certain embodiments, the non-woven multilayer composite comprises two or more of the recycled layers.

[0033] In certain embodiments, the fiber blend of all cycles of steps (a) to (c) consists of one or more non-melt fibers.

[0034] In certain embodiments, the fiber blend of all cycles of steps (a) to (c) consists of one or more thermal melt fibers or polymers.

[0035] In certain embodiments, the fiber blend in any cycle of steps (a) to (c) comprises or consists of one or more thermal melt fibers or polymers.

[0036] In certain embodiments, the one of more thermal melt fibers or polymers comprise polypropylene, polylactic acid, polyethylene, a bi-component polyester, a bi-component inner core of polyester, an outer core of polypropylene, or any combination thereof.

[0037] In certain embodiments, the one or more thermal melt fibers or polymers is polypropylene.

[0038] In certain embodiments, the one or more thermal melt fibers or polymers are non-crimped and are between about 2 denier and about 3 denier.

[0039] In certain embodiments, the fiber blend in any cycle of steps (a) to (c) comprises or consists of one or more non-melt fibers. [0040] In certain embodiments, the one of more non-melt fibers comprise a natural fiber, a polyester fiber, or a combination thereof. In certain embodiments, the natural fiber comprises a plantbased fiber. In certain embodiments, the plant-based fiber is from hemp, kenaf, jute, bamboo, or any combination thereof. In certain embodiments, the plant-based fiber is a bast fiber. In certain embodiments, the one or more non-melt fibers are about 30 mm in length.

[0041] In certain embodiments, in step (b) the laying of the web of the discharged fiber blend is at a different surface density weight in one or more of the cycles of steps (a) to (c).

[0042] In certain embodiments, the process further comprises a step of infusing a thermal set resin into one or more of the composite layers after any cycle of steps (a) to (c).

[0043] In certain embodiments, the thermal set resin comprises a latex formulation, an acrylic formulation, or a formulation of both latex and acrylic.

[0044] In certain embodiments, the process further comprises after step (d), a step of: (e) amalgamating individual fibers in the non-woven multilayer composite to provide in-direction tensile strength, to intertwine fibers within or between composite layers, and/or to receive one or more resins.

[0045] In certain embodiments, the process further comprises after step (e), a step of: (f) infusing the one or more resins into the amalgamated individual fibers of the non-woven multilayer composite. In certain embodiments, the one or more resins comprise a thermal set resin. In certain embodiments, the thermal set resin comprises a latex formulation, an acrylic formulation, or a formulation of both latex and acrylic.

[0046] In certain embodiments, the infusing of the one or more resins comprise:

(fl) transforming the one or more resins from a liquid to a foam; and (12) infusing the foam into the amalgamated individual fibers of the non-woven multilayer composite. In certain embodiments, the foam is infused into the composite from both sides of the non-woven multilayer composite.

[0047] In certain embodiments, the process further comprises a step of: (g) removing liquid from the non-woven multilayer composite. In certain embodiments, the step of removing liquid is by using radio frequency waves.

[0048] In certain embodiments, the process further comprises a step of introducing an additive into one or more of the composite layers after any cycle of steps (a) to (c). In certain embodiments, the additive is an organic compound, a flame -retardant, a colorant, a water repellant, or any combination thereof. In an embodiment, the organic compound is maleic anhydride or an acidic form thereof.

[0049] In certain embodiments, step (a) of providing the fiber blend comprises: (al) debating the one or more fiber materials to decompress the fibers and provide a debaled fiber; (a2) blending two or more different types of the debaled fiber in a blend line to provide the fiber blend; (a3) transferring the fiber blend by air to a storage vessel; and (a4) transferring the fiber blend from the storage vessel the fiber scattering assembly as required. In certain embodiments, blending comprises providing the two or more different types of the debaled fiber to a rotating wire cylinder.

[0050] In certain embodiments, the prepared non-woven multilayer composite has a substantially equal strength in both the x direction and the y direction.

[0051] In certain embodiments, each composite layer of the prepared multilayer composite is substantially equal in strength in both the x direction and the y direction.

[0052] In certain embodiments, the prepared non-woven multilayer composite has one or more of the following properties: increased screw retention as compared with other composite products; provides UL94 protection from burning; reduced composite weight as compared with other composite products; reduced acquisition cost as compared with other composite products, made using carbon sequestering fibers; substantially carbon neutral or carbon negative; and is fully recyclable.

[0053] In an embodiment, the present disclosure relates to a system for preparing a non-woven multilayer composite, the system comprises: two or more fiber scattering assemblies in sequence with each other, each of the fiber scattering assemblies for receiving and layering a fiber blend; and one or more belts operationally associated with the two or more fiber scattering assemblies, the belts configured to provide a previously laid composite layer from an earlier fiber scattering assembly in the sequence to a later fiber scattering assembly in the sequence, wherein each of the later fiber scattering assemblies in the sequence are configured to layer a composite layer atop the previously laid composite layer(s) to provide the non-woven multilayer composite.

[0054] In certain embodiments, each of the two or more fiber scattering assemblies comprises a load cell for regulating the amount of a discharged fiber blend from the fiber scattering assembly to form the composite layer. [0055] In certain embodiments, each of the two or more fiber scattering assemblies comprises a web forming device for receiving the fiber blend from the load cell and laying the fiber blend in a non- directional arrangement in the composite layer.

[0056] In certain embodiments, each of the fiber scattering assemblies comprises: a feed tower from which the fiber blend is supplied to the load cell; and a programmable logic controller (PLC) for controlling the fiber scattering assembly.

[0057] In certain embodiments, each of the fiber scattering assemblies comprises an input weigh scale in communication with the PLC for regulating the amount of the fiber blend delivered to the load cell from the feed tower and/or the speed of the one or more belts operationally associated with the two or more fiber scattering assemblies.

[0058] In certain embodiments, the system comprises three, four, five, six, seven or more of the fiber scattering assemblies.

[0059] In certain embodiments, the one or more belts comprises: one or more conveying belts for laying thereon the fiber blend to provide the composite layer and/or for transferring the composite layer onwards in the system; and a degassing belt for contacting the composite layer on an opposite side to that which contacts the conveying belt.

[0060] In certain embodiments, the degassing belt is adjustable at one or both of an upstream end and a downstream end to reduce or increase the space between the conveying belt and the degassing belt at each end.

[0061] In certain embodiments, when in operation, the downstream end of the degassing belt is positioned closer to the conveyer belt than the upstream end.

[0062] In certain embodiments, when in operation, the degassing belt is run at a different speed than the conveying belt. In certain embodiments, when in operation, the degassing belt is run at a slower speed than the conveying belt so as to drag and cause a regression on a top surface of the composite layer.

[0063] In certain embodiments, the system disclosed herein further comprises an output weigh scale to monitor the weight of the composite layer provided by each of the two or more fiber scattering assemblies. [0064] In certain embodiments, the system further comprises a recycler assembly in place of one or more of the fiber scattering assemblies, the recycler assembly for receiving a recycled feed material comprising a recycled trim waste, an end of life material, or any combination thereof, and laying the recycled feed material layer atop one or more of the previously laid composite layer(s).

[0065] In certain embodiments, the recycler assembly is one or more of the fiber scattering assemblies, and the recycled feed material additionally comprises the fiber blend.

[0066] In certain embodiments in which the system comprises seven fiber scattering assemblies in sequence, and the fourth fiber scattering assembly in the sequence is a recycler assembly.

[0067] In certain embodiments, the recycler assembly is a separate component from the fiber scattering assemblies, and the recycled feed material is free of the fiber blend.

[0068] In certain embodiments, the system comprises in sequence: three fiber scattering assemblies, the recycler assembly, and a further three fiber scattering assemblies.

[0069] In certain embodiments, the system further comprises a loom downstream in sequence from the two or more fiber scattering assemblies, the loom for amalgamating individual fibers in the non-woven multilayer composite to provide in-direction tensile strength, to intertwine fibers within or between composite layers, and/or to receive one or more resins. In certain embodiments, the loom is a hyper punch needle loom.

[0070] In certain embodiments, the system further comprises a foam injection applicator for infusing a foam of the one or more resins into the non-woven multilayer composite.

[0071] In certain embodiments, the one or more resins comprise a thermal set resin. In certain embodiments, the thermal set resin comprises a latex formulation, an acrylic formulation, or a formulation of both latex and acrylic.

[0072] In certain embodiments, the foam injection applicator is positioned on both sides of the non-woven multilayer composite such that, when in operation, the foam is infused into the non-woven multilayer composite from both sides. In certain embodiments, in operation, the foam is infused into both sides sequentially or in combination.

[0073] In certain embodiments, the one or more resins comprise an additive. In certain embodiments, the additive is an organic compound, a flame -retardant, a colorant, a water repellant, waste, or any combination thereof. In certain embodiments, the waste comprises any by-product produced using a system or performing a process as described herein. In certain embodiments, the waste comprises waste water, resin or diluted resin. In an embodiment, the organic compound is maleic anhydride or an acidic form thereof.

[0074] In certain embodiments, the system further comprises: (g) one or more radio frequency generators downstream in sequence from the two or more fiber scattering assemblies for applying radio waves for removing liquid from the non-woven multilayer composite.

[0075] In certain embodiments, the system further comprises one or more debalers and a blend line assembly for preparing the fiber blend and delivering the fiber blend to each of the two or more fiber scattering assemblies. In certain embodiments, the system comprises a synthetic fiber debaler and a cellulose fiber debaler. In certain embodiments, each of the debalers comprises a fiber opener, a weigh scale, or both.

[0076] In certain embodiments, the blend line comprises a rotating wire cylinder for blending the fiber blend in a homogeneous mixture.

[0077] In certain embodiments, for each of the fiber scattering assemblies there is a separate and independent assembly of the one or more debalers and the blend line.

[0078] In certain embodiments, in operation, each of the separate and independent assemblies of the one or more debalers and the blend line provides a different fiber blend to each of the fiber scattering assemblies.

[0079] In certain embodiments, in operation, two or more of the separate and independent assemblies of the one or more debalers and the blend line provides the same fiber blend to two or more of the fiber scattering assemblies.

[0080] In certain embodiments, in operation, a first and last fiber scattering assembly, in the sequence of fiber scattering assemblies, is provided the same fiber blend.

[0081] In certain embodiments, the non-woven multilayer composite comprises, two or more of the composite layers that are of the same fiber blend and two or more of the composite layers are of a different fiber blend. [0082] In certain embodiments, the system is capable of laying each of the composite layers at a different surface density weight.

[0083] In certain embodiments, the system is capable of preparing the non-woven multilayer composite with the composite layers having a surface density variation of less than 10% per layer. In certain embodiments, the system is capable of preparing the non-woven multilayer composite with the composite layers having a surface density variation of less than 5% per layer. In certain embodiments, the system is capable of preparing the non-woven multilayer composite with the composite layers having a surface density variation of less than 2% per layer.

[0084] In certain embodiments, the system is capable of preparing the non-woven multilayer at an area density (gsm) that is within +/- 5% of a target density.

[0085] In certain embodiments, the fiber blend in any one or more of the composite layers comprises or consists of one or more thermal melt fibers or polymers. In certain embodiments, the one of more thermal melt fibers or polymers comprises polypropylene, polylactic acid, polyethylene, a bicomponent polyester, a bi-component inner core of polyester, an outer core of polypropylene, or any combination thereof. In certain embodiments, the one or more thermal melt fibers or polymers is polypropylene. In certain embodiments, the one or more thermal melt fibers or polymers are noncrimped and are between about 2 denier and about 3 denier.

[0086] In certain embodiments, the fiber blend in any one or more of the composite layers comprises or consists of one or more non- melt fibers. In certain embodiments, the one of more non-melt fibers comprise a natural fiber, a polyester fiber, or a combination thereof. In certain embodiments, the natural fiber comprises a plant-based fiber. In certain embodiments, the plant-based fiber is from hemp, kenaf, jute, bamboo, or any combination thereof. In certain embodiments, the plant-based fiber is a bast fiber. In certain embodiments, the one or more non-melt fibers are about 30 mm in length.

[0087] In certain embodiments, the non-woven multilayer composite has substantially equal strength in both the x direction and the y direction.

[0088] In certain embodiments, each composite layer in the non-woven multilayer composite has substantially equal in strength in both the x direction and the y direction.

[0089] In an embodiment, the present disclosure relates to a non-woven multilayer composite prepared according to the process as described herein. [0090] In an embodiment, the present disclosure relates to a non-woven multilayer composite prepared using the system as described herein.

[0091] In an embodiment, the present disclosure relates to a non-woven multilayer composite which comprises at least two composite layers, wherein the fibers of each composite layer are substantially non-directional in arrangement.

[0092] In certain embodiments, the non-woven multilayer composite comprises at least three, four, five, six, seven or more of the composite layers.

[0093] In certain embodiments, wherein each of the layers of the non-woven composite is made of the same fiber blend, the fiber blend comprising a non-melt fiber and a thermal melt fiber or polymer to provide a thermal melt composite.

[0094] In certain embodiments, each of the layers of the non-woven multilayer composite is made of one or more non-melt fibers infused with thermal set resins to provide a thermal set composite.

[0095] In certain embodiments, wherein two or more of the composite layers of the non-woven multilayer composite are made from a different fiber blend, each fiber blend comprises different types of fibers and/or amounts of fibers.

[0096] In certain embodiments, wherein each of the composite layers of the non-woven multilayer composite is made from a different fiber blend, each fiber blend comprises different types of fibers and/or amounts of fibers.

[0097] In certain embodiments, the non-woven multilayer composite, which is a combined thermal melt and thermal set composite, at least one layer comprising thermal melt fibers or polymers and at least one layer comprising non-melt fibers with infused thermal set resins.

[0098] In certain embodiments, each outer layer of the non-woven multilayer composite comprises the non-melt fibers with infused thermal set resins, and two or more inner layers comprise the thermal melt fibers or polymers.

[0099] In certain embodiments, the thermal melt fiber or polymer of the non-woven multilayer composite is polypropylene.

[0100] In certain embodiments, the thermal melt fiber or polymer is non-crimped. In certain embodiments, the one or more thermal melt fibers or polymers are between about 2 denier and about 3 denier. In certain embodiments, the one or more thermal melt fibers or polymers are about 2 denier. In certain embodiments, the one or more thermal melt fibers or polymers are between about 20 mm and about 30 mm in length. In certain embodiments, the one or more thermal melt fibers or polymers are about 25 mm in length.

[0101] In certain embodiments, the one of more non-melt fibers comprise a natural fiber, a polyester fiber, or a combination thereof. In certain embodiments, the natural fiber comprises a plant-based fiber. In certain embodiments, the plant -based fiber is from hemp, kenaf, jute, bamboo, or any combination thereof. In certain embodiments, the plant-based fiber is a bast fiber. In certain embodiments, the one or more non-melt fibers are about 30 mm in length.

[0102] In certain embodiments, two or more of the composite layers of the non-woven multilayer composite are at a different surface density weight.

[0103] In certain embodiments, each of the composite layers of the non-woven multilayer composite is at a different surface density weight.

[0104] In certain embodiments, wherein at least one layer of the non-woven multilayer composite comprises a recycled feed material, the recycled feed material comprises a recycled trim waste, an end of life material, or any combination thereof.

[0105] In certain embodiments, the non-woven multilayer composite has substantially equal strength in both the x direction and the y direction.

[0106] In certain embodiments, each composite layer in the non-woven multilayer composite has substantially equal in strength in both the x direction and the y direction.

[0107] In certain embodiments, the non-woven multilayer composite has one or more of the following properties: increased screw retention as compared with other composite products; provides UL94 protection from burning; reduced composite weight as compared with other composite products; reduced acquisition cost as compared with other composite products, made using carbon sequestering fibers; substantially carbon neutral or carbon negative; and is fully recyclable.

[0108] In an embodiment, the present disclosure relates to a non-woven multilayer composite comprising at least two composite layers, wherein each of the at least two composite layers comprises: (i) a thermal melt fiber or polymer that is non-crimped and is between about 2 denier and about 4 denier; and (ii) one or more non-melt fibers are about 30 mm in length. [0109] Other aspects and features of the non-woven multilayer composites, processes and systems of the present disclosure will become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

[0110] These and other features of the present invention will be further understood with reference to the following description and accompanying drawings. The appended drawings illustrate one or more embodiments of the present disclosure by way of example and are not to be construed as limiting the scope of the present disclosure, wherein:

[0111] FIG. 1 shows a schematic diagram of an embodiment of a fiber scattering assembly of the present disclosure, in which the degassing belt is adjacent the web forming device.

[0112] FIG. 2 shows a schematic diagram of another embodiment of a fiber scattering assembly of the present disclosure, in which the degassing belt is downstream on the main line conveyer belt with the degassing belt angled upwards at the downstream end.

[0113] FIG. 3 shows a schematic diagram of another embodiment of a fiber scattering assembly of the present disclosure, in which the degassing belt is on a conveying belt adjacent the web forming device, but is position slightly downstream on the belt and is angled downwards towards the conveying belt at the downstream end.

[0114] FIG. 4 shows a schematic diagram of another embodiment of a fiber scattering assembly of the present disclosure, which includes both an input weigh scale and an output weigh scale.

[0115] FIG. 5 shows a schematic diagram of an embodiment of a system disclosed herein for preparing a multilayer composite as described herein, whereby the system is configured to produce a multilayer composite comprising two composite layers.

[0116] FIG. 6 shows a schematic diagram of an embodiment of a system disclosed herein for preparing a multilayer composite as described herein, whereby the system is configured to provide a multilayer composite comprising six composite layers.

[0117] FIG. 7 shows a side view schematic diagram of an embodiment of a system disclosed herein for preparing a multilayer composite as described herein, whereby the system is configured to provide a multilayer composite comprising seven layers with one of the layers comprising a recycled feed material.

[0118] FIG. 8 shows a top view of the system of FIG. 7, showing each of the blend line feed towers alternating between opposite sides for each fiber scattering assembly in sequence in the system.

[0119] FIG. 9 shows a schematic diagram of an embodiment of a fiber scattering assembly and further downstream processing features of the present disclosure, including an edge trimmer, an endline degassing belt, a loom, a surface density scanner / line speed tension control device, a form injection applicator, and a radio frequency generator.

[0120] FIG. 10 shows a schematic diagram of an embodiments of upstream processing features of the present disclosure, including a debaler, one or more blend belts, a blend line assembly (within dashed box), and a fiber blend delivery tube.

[0121] FIG. 11 shows a schematic diagram of another embodiment of upstream processing features of the present disclosure, including a synthetic fiber debaler, a cellulose fiber debaler, one or more blend belts, a blend line assembly (within dashed box), and a fiber blend delivery tube.

[0122] FIG. 12 shows a schematic flow diagram of an embodiment of the processes as disclosed herein.

DETAILED DESCRIPTION

[0123] Described herein are non-woven multilayer composites, as well as systems and processes for the preparation thereof. It will be appreciated that embodiments and examples are provided herein for illustrative purposes intended for those skilled in the art, and are not meant to be limiting in any way.

Definitions

[0124] Unless otherwise defined, all technical and scientific terms used herein generally have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. Exemplary terms are defined below for ease in understanding the subject matter of the present disclosure.

[0125] In the present disclosure, all terms referred to in singular form are meant to encompass plural forms of the same. Likewise, all terms referred to in plural form are meant to encompass singular forms of the same. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0126] It should be understood that the non-woven multilayer composites, systems and processes are described in terms of “comprising,” “containing,” or “including” various components or steps meaning that they may also contain additional features, components or steps, but that the non-woven multilayer composites, systems and processes can also “consist essentially of’ or “consist of the various components and steps”. Moreover, the indefinite articles "a" or "an," as used in the claims, are defined herein to mean one or more than one of the element that it introduces.

[0127] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, "from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

[0128] Many obvious variations of the embodiments set out herein will suggest themselves to those skilled in the art in light of the present disclosure. Such obvious variations are within the full intended scope of the appended claims.

[0129] As used herein, the term “about” refers to an approximately +/-10 % variation from a given value. It is to be understood that such a variation is always included in any given value provided herein, whether or not it is specifically referred to.

[0130] As used herein, the term “substantially” refers to an approximately +/-5 % variation from a given value. If a value is not used, then substantially means almost completely, but perhaps with some variation, contamination and/or additional component. In some embodiments, “substantially” may include completely. It is to be understood that such a variation is always included in any given value provided herein, whether or not it is specifically referred to.

[0131] As used herein, the term “different” when in reference to any feature, step, component, quantitative measure, numerical value or other, has its common meaning of not the same or not identical.

[0132] As used herein, the term “non-woven” in reference to a multilayer composite or layer thereof, has an ordinary meaning of the fibers not being woven together, for example was not created with one or more of the following: using weaving, warp and weft threads, or an interlaced fiber pattern.

[0133] As used herein, the term “composite” may refer to anything composed of two or more different components.

[0134] As used herein, the term “layer” may refer to a single sheet, or thickness of material.

As used herein, the term “multilayer” may refer to the combination of two or more layers in one product, material, composite or any equivalent thereof. In the context of the present disclosure, reference to a “multilayer composite” of the present disclosure shall be taken as referring to a “non-woven multilayer composite”, as the terms are used interchangeably herein when referring to the multilayer composites of the present disclosure. A layer may comprise a web or web layer, or comprise laying the layer as a web or web layer. By “web” or “web layer”, it is meant a laid down collection of fibers in which there is a network of fibers intertwined in a non-woven manner with each other to form a layer. In an embodiment, while being non-directional, the web is generally homogenous throughout the layer.

[0135] As used herein, the term “fiber” may refer to any natural, synthetic or other fiber. In an embodiment, the fiber may be obtained or derived from a plant material. The fiber may be a long or short natural or synthetic thread, filament or other conformation, an element that gives texture or substance, a structural element, or any combination thereof. In an embodiment, and without limitation, the fiber is a non-melt fiber, a melt fiber, a polyester fiber, a binding fiber, a carbon sequestering fiber, a carbon neutral fiber, or any other fiber that may be available. As described herein, a “fiber material” may be any material that comprises fiber, together or without any other materials. A “fiber blend” may be any prepared substance that comprises the one or more fiber materials and, as such, may refer to a fiber preparation comprising one or more types of fiber. A fiber blend may be substantially homogenous such that each fiber material is distributed substantially uniformly within the fiber blend. As mentioned, the fiber blend may comprise a single fiber material or two or more different fiber materials. Each layer of the multilayer composite herein may comprise a fiber blend of a single fiber material, or two or more different fiber materials. Likewise, as compared to one another, each layer of the multilayer composite may the same or different fiber blends.

[0136] As used herein, the expression “non-melt fiber” retains its meaning as known in the art and for example may refer to any fiber that typically does not melt upon moderate application of heat. In an embodiment, it is a natural fiber, synthetic fiber, or combination thereof (e.g. derived from modification to a natural fiber). In an embodiment, the non-melt fiber is derived from a plant, such as a bast fiber. In an embodiment, the non-melt fiber may be polyester. In an embodiment, the non-melt fiber may be a hemp bast fiber.

[0137] As used herein, the expression “bast fiber” may refer to any plant fiber collected from the bast component of a plant, and may include fibers from other components or layers of the plant as well. In an embodiment, the term “bast fiber” refers to a fiber material comprising at least 80% by weight of fibers from the bast component of a plant, more particularly at least 95% by weight, and more particularly still at least 99% by weight. In an embodiment, the bast fiber consists of fibers from the bast component of a plant. Without limitation, examples of plants containing bast fibers include hemp, cannabis, kenaf, jute, bamboo, flax, ramie, roselle, sunn, linden, nettle, okra, milkweed, paper mulberry, or linen. The bast fiber herein may be from one of these types of plants or a mixture from any combination thereof. Since plants, such as those producing bast fibers, absorb carbon from the air, bast fibers such as hemp for example, can sequester carbon when used in the multilayer composites herein. Carbon may become ‘locked’ in the bast fiber or other carbon sequestering fiber and therefore any composite manufactured from bast fiber, or other carbon sequestering fiber, continues to retain sequestered carbon.

[0138] As used herein, the expression “thermal melt fiber or polymer” retains its meaning as known in the art and for example may refer to any fiber, polymer or mixture thereof that melts upon application of heat. In an embodiment, the heat must be at least 100°C, more particularly at least 110°C, more particularly still at least 170°C, and even more particularly still at least 200°C. In an embodiment, the heat is about 200°C. In an embodiment, the thermal melt fiber may comprise any fiber material, which is obtained, created or spun with a solution of a polymer, wherein said polymer solution solidifies by any process known in the art, such as, but not limited to air removal, gas removal, liquid removal or temperature change, to produce the thermal melt fiber. In certain embodiments herein, the “melt fiber” may be a synthetic fiber made from or with a synthetic polymer or the “melt fiber” may be a non-synthetic fiber made from or with a non-synthetic polymer. In an embodiment, the thermal melt fiber may be a recyclable or a recycled fiber. Examples of thermal melt fibers or polymers include, but are not limited to, polypropylene, polylactic acid (PLA), polyethylene, polyester, bi-component polyesters, or bi-component with an inner core of polyester and outer core of polypropylene.

[0139] As used herein, the term “resin” may refer to a solid or viscous liquid substance of either synthetic or natural origin, which is typically convertible into polymers. As used herein, the expression “thermal set resin” retains its meaning as known in the art and for example may refer to a resin, which is capable or being liquefied upon addition of heat and which solidifies again upon cooling. For example, upon application of heat the resin may form a liquid monomer or prepolymer, but then hardens or turns into a solid when exposed to one or more of: cooling or an additive (e.g. chemical additive), or other technique known by a person of skill in the art. Examples of thermal set resins include, but are not limited to, a latex or acrylic formulation, or a blend of both latex and acrylic. Typically, a thermal set resin is capable of and may re-soften and/or remold at temperatures greater than 360 degrees Fahrenheit (about 180°C).

[0140] As used herein, the term “blending” may refer to the mixing or breaking apart and dispersing of one or more materials (e.g. fibers), such that the one or more materials are substantially homogenously mixed or dispersed. Blending may be performed using a blend line or blend line assembly, such as those described herein.

[0141] As used herein, the term “belt” may refer to a continuous band of material or may refer to any collection of components that are capable of delivering an item from one location to another. In an embodiment, the belt may be an apron feeder. In an embodiment, the belt may be a spike apron belt or spike apron feeder. In an embodiment, the belt may be a belt feeder having a continuous belt disposed thereon.

[0142] As used herein, the term “degassing” may refer to any process for the removal of a gas from a solid or liquid, for example for removal of a dissolved gas. In some embodiments, the term “degassing” may comprise both the conversion of a liquid to a gas and the removal of the gas.

[0143] As used herein, the term “infusing” may refer to the addition of a solid, a liquid, a foam, or a gas into a material, such as a composite layer or multiplayer composite of the present disclosure. In an embodiment, the solid, liquid, foam, or gas is received internally in the material, such as by injection.

[0144] As used herein, the phrase “surface density” refers to the area density and/or the mass per unit area or per unit volume. In the context of the present disclosure, the surface density may be in relation to each individual layer of the multilayer composite, whereby each individual layer may have the same or different surface density than another layer. In other embodiments, the surface density may be of all combined layers within a multilayer composite. It is contemplated in embodiments herein that the surface density may comprise the mass of a substance, such as a fiber blend, per unit volume or per unit area. The person of skill in the art, in light of the teachings herein, will appreciate that changes in surface density may have significant impacts on the properties of composites and therefore the ability to maintain a desired surface density in one or more composite layers, or for all layers in combination, may be advantageous.

[0145] As used herein, the term “grinding” may refer to any process known in the art or science to produce a ground material, wherein the ground material is substantially smaller than the material prior to the grinding. In certain embodiments, grinding may reduce a particle size to between about 0.1 mm and about 5.0 mm, or more particularly between about 0.5 mm and about 1.0 mm.

[0146] As used herein, “recycled trim waste” may refer to the trim waste of a previously prepared single or multilayer composite as prepared by any process, which is used in the processes, systems and multilayer composites of the present disclosure as a recycled material. The trim waste may, for example, be cuttings or trim products from a previously produced multilayer composite of the present disclosure that is ground, cut or otherwise restored to a suitable size for reintroduction into a subsequent multilayer composite in accordance with the processes and systems herein.

[0147] As used herein, the phrase “end of life material” may refer to any material of a previously produced product that is no longer needed, is garbage, or is desired to be recycled. The end of life material may be any recycled material or recyclable material as described herein. In an embodiment, the end of life material is no longer desired by industry or users in its existing form or no longer sufficiently functions as originally intended. For example, in an embodiment, the end of life material may be any material treated as garbage or waste or any material that may be a recyclable material. Without limitation, the end of life material may be or comprise a portion of a single layer composite, a woven or non-woven multilayer composite, a plastic, a synthetic material, a polymer-based material, or any combination thereof. In an embodiment, the end of life material may be from an interior material of an automobile (e.g. dashboard, door panels, etc.), a component of a recreational vehicle (RV), or any other suitable material. In an embodiment, the end of life material may be a previously recycled material. [0148] As used herein, the expression “recyclable material” may refer to any material that is capable of being processed and then used in a different, similar or identical form as originally intended for the material. In an embodiment, the recyclable material is a recyclable fiber or recyclable fiber blend. As used herein, the expression “recycled material” may refer to any material that has already been used in a different, similar or identical form prior to being used in any of the embodiments described herein. In an embodiment, the recycled material is a recycled fiber or recycled fiber blend. As would be known to a person of skill in the art, there are multiple techniques for recycling a recyclable material, and the person of skill in the art, in light of the teachings herein, will be able to select an appropriate recycling method or material for a given application, taking into consideration factors such as fiber -type and desired product. The inclusion of recycled material or recyclable material in a fiber blend, composite layer, or multilayer composite of the present disclosure may decrease the need for a new and potentially more costly material or fiber, or an environmentally detrimental material or fiber. Recyclable or recycled material, such as a fiber, may impart other beneficial properties to the fiber blend, composite layer, and/or multilayer composite when compared to those products produced without said material, including decreased weight, increased durability, improved recyclability, and/or increased strength. For example, an embodiment described herein may use natural fiber (for example, a bast fiber) to replace a resin that may be generally used with conventional techniques (for example, a polypropylene resin). The natural fiber may sequester carbon, and eliminate the use of carbon derived polymer from the resin.

[0149] As used herein, a “recycled feed material” refers to any material comprising or consisting of recycled trim waste, end of life material, or any combination thereof. The recycled feed material may comprise any percentage by weight or by volume of the recycled trim waste and/or end of life material. In an embodiment, the recycled feed material comprises at least 1%, at least 5%, at least 10%, at least 20%, at least 25%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, at least 96%, at least 97%, at least 98%, at least 99%, or 100% of the recycled trim waste and/or end of life material. In an embodiment, the recycled feed material comprises between about 25% and about 100%, more particularly between about 50% and about 100%, and more particularly still between about 75% and about 100% of the recycled trim waste and/or end of life material. In an embodiment, the recycled feed material comprises a fiber blend as described herein, or depending on percentages, the fiber blend comprises the recycled feed material. In an embodiment, the recycled feed material consists of recycled trim waste and/or end of life material.

[0150] As used herein, “a portion of a recycled or recyclable material” may comprise any amount of recycled or recyclable material included in a fiber blend, composite layer, or multilayer composite ranging from about 0.001% to 100%. The use of an increased proportion of a recycled or recyclable material may improve the environmental related features of the fiber blend, composite layer, or multilayer composite, such that it has a decreased negative impact on the environment when compared with those produced with a lower percentage of recycled or recyclable material.

[0151] As used herein, “non-directional” is intended to refer to a random, disorganized, or non-uniform orientation of fibers relative to each other. By “non-directional in arrangement” it is intended to mean that when laid in a composite layer, the arrangement of the fibers within the composite layer is random, disorganized or non-uniform. In an embodiment, the fibers may be non-directional in a 2-dimensional space (or plane). In an embodiment, the fibers may be non-directional in a 3-dimensional space. In an embodiment, non-directional may refer to a composite with substantially equal tensile strength in both the X direction and the Y direction. Herein, tensile strength refers to the capacity of a material, layer, composite, multilayer composite or equivalent or product produced therefrom to resist breaking under tension. Herein, the X and Y directions refer to the axis of the multilayer composite as would be appreciated by a person of skill in the art.

[0152] As used herein, the term “dispersed” or “dispersal” or “disperse” may comprise the distribution of material from one location to a different location such that the material is substantially evenly spaced across a region, such as for example, a layer, a feeder, or a belt.

[0153] As used herein, “UL94” may refer to a standard for safety of flammability of plastic materials for parts in devices and appliances. UL94 may determine the materials tendency to either extinguish flames or spread flames once the material has been ignited. A person of skill in the art would be aware of other suitable flammability standards, such as, but not limited to, IEC 60695-11-10, IEC 60695-11-20, ISO 9772, ISO 9773 or other flammability standards applicable to any jurisdiction.

[0154] Systems and Processes

[0155] In an embodiment, the present disclosure relates to a process for preparing a non-woven multilayer composite, the process comprising steps of: (a) providing a fiber blend comprising one or more fiber materials to a fiber scattering assembly, the fiber scattering assembly comprising comprise a load cell that regulates the amount of a discharged fiber blend from the fiber scattering assembly; (b) laying a web of the discharged fiber blend from the fiber scattering assembly to form a composite layer; (c) delivering the composite layer to another of the fiber scattering assemblies as a previously laid composite layer; (d) repeating steps (a) to (c) one or more times using the previously laid composite layer(s) as a substrate for layering atop thereof each subsequent composite layer to provide a plurality of layers forming the non-woven multilayer composite, wherein the fiber blend used for each successive composite layer is the same or different than the fiber blend used in any of the previously laid composite layers.

[0156] In another embodiment, the present disclosure relates to a system for preparing a non-woven multilayer composite, the system comprising: two or more fiber scattering assemblies in sequence with each other, each of the fiber scattering assemblies for receiving and layering a fiber blend; and one or more belts operationally associated with the two or more fiber scattering assemblies, the belts configured to provide a previously laid composite layer from an earlier fiber scattering assembly in the sequence to a later fiber scattering assembly in the sequence, wherein each of the later fiber scattering assemblies in the sequence are configured to layer a composite layer atop the previously laid composite layer(s) to provide the multilayer composite.

[0157] As used herein, the phrases “in sequence”, “in the sequence”, or “in series” may refer to the location of a component (e.g. fiber scattering assembly, recycler assembly, etc.) in the system and/or the temporal use of the component or step in the process. The terms “upstream” and “downstream” may refer to the positioning within the system and/or the temporal use during the process.

[0158] As will be appreciated, any description herein relating to processes of the present disclosure may be equally applicable and descriptive of systems of the present disclosure, and vice versa. Likewise, any description herein relating to processes or systems of the present disclosure should be understood as providing any number of different multilayer composites. Indeed, the processes and systems of the present disclosure unlock infinite combinations of fiber blends, resin types and composite layers that may be included within a single multilayer composite, including multilayer composites of combined thermal melt layers, thermal set layers, and/or layers of a recycled feed material. The systems and processes herein uniquely and advantageously allow for mismatching of fiber types in each layer, including the inclusion of the two different types of binding approaches (e.g. thermal melt fibers versus thermal set resins) within a single multilayer composite.

[0159] A person of skill in the art would appreciate that binding fibers, such as polypropylene fiber, used for traditional non-woven manufacturing have a shaft thickness, which is referred to in the art as denier, of 4 to 6 denier. Additionally, a person of skill would appreciate that the fiber cut length is also important to increase fiber count, and nominal fiber length in conventional non-woven manufacturing is about 1.5 to 2.5 inches. [0160] In certain embodiments described herein, fibers of the fiber blends used in the processes and systems will have a denier of less than 4. In an embodiment, the fibers of the fiber blends herein have a denier of between about 1 and about 4. In an embodiment, the fibers of the fiber blends herein have a denier of between about 2 and about 3. In an embodiment, the fibers of the fiber blends herein have a denier of about 2. Traditional non-woven composites of a similar fiber formulation are restricted to running greater than 4 denier, and more often greater than 6 denier, to avoid pilling. In embodiments of the systems and processes of the present disclosure, a lower denier may be used and the system and processes are capable of obtaining no pilling of areas involved. The piling has been eliminated.

[0161] In certain embodiments described herein, the fiber cut length is equal to or less than 1 inch. In certain embodiments, the fiber cut length is less than 100 mm, more particularly less than 50 mm, and more particularly still less than 25 mm. In an embodiment, the fiber cut length is between about 15 mm and about 50 mm, and more particularly between about 20 mm and about 30 mm. In an embodiment, the fiber cut length is about 15 mm, about 20 mm, about 25 mm, about 30 mm, about 35 mm, about 40 mm, about 45 mm, or about 50 mm. In an embodiment, the fiber cut length of non-melt fibers used in the fiber blends herein is about 30 mm. In an embodiment, the fiber cut length of thermal melt fibers used in the fiber blends herein is about 25 mm. The use of shorter fiber lengths may provide an increase in fiber count content, which is an advantageous aspect capable of being achieved with the processes and systems disclosed herein.

[0162] Traditional techniques may also use fiber crimping. Fibers that do not require crimping may allow complete separation of fibers or near complete separation of fibers, which may permit full homogenous blending of each fiber type. Non-crimp fiber also means synthetic fibers are much easier to open and less problematic. In an embodiment, all of the fibers used in the fiber blends of the present disclosure are non-crimped. In an embodiment, the thermal melt fibers or polymers used in the fiber blends of the present disclosure are non-crimped. In an embodiment of the present disclosure, the fiber cut length non-crimp is about 24 mm.

[0163] Advantageously, the present disclosure presents concepts for multilayer composite construction and customization to precisely fit numerous different applications and requirements, including multilayer composites with improved screw retention and/or flexural modulus. For example, multilayer composites of the present disclosure may comprise inner layers made with thermal melt binder (e.g. thermal fibers or polymers) and one or both outer layers made with thermal set binders (e.g. non-melt fibers with thermal set resins), or vice versa. The thermal set layers can provide stiffness, while the thermal melt layers can provide improved screw retention, all within a single multilayer composite. As well, layers of recycled feed material may be included as one or more internal or external layers. Thus, not only are the multilayer composites herein themselves capable of carbon sequestration, but also recycled material having sequestered carbon therein can be locked away within an internal layer of the multilayer composites herein, to thereby retain the prior environmental benefits. The recyclable or recycled material with sequestered carbon can be a recycled feed material time and time again in accordance with embodiments of the present disclosure.

[0164] Also advantageously, the system and process of the present disclosure maximizes fiber count, which provides for extraordinary homogenous blends. In addition, in embodiments, the x and y strength differences are neutral in the multilayer composites herein and the strength:weight is about 20% higher than conventional non-woven materials of equal or similar weight and formulation.

[0165] Reference will now be made in detail to exemplary embodiments of the disclosure, wherein numerals refer to like components, examples of which are illustrated in the accompanying drawings that further show exemplary embodiments, without limitation.

[0166] FIGs. 1-4 are schematic drawings of exemplary fiber scattering assemblies 1 of the present disclosure. In an embodiment, the fiber scattering assembly 1 comprises a load cell 2, a feed tower 3 and a programmable logical controller (PLC) 4. The fiber scattering assembly 1 may be of any suitable design or configuration for laying down a layer of a fiber blend in a controlled and regulated manner. The processes and systems of the present disclosure include at least two or more of the fiber scattering assemblies 1, such that a composite layer from upstream fiber scattering assemblies 1 are delivered to downstream fiber scattering assemblies 1 to sequentially add composite layers atop each other and form the multilayer composite.

[0167] In an embodiment, the fiber scattering assembly 1 comprises a feed tower 3 that stores and/or delivers a fiber blend to a load cell 2. The feed tower 3 may be an individual component of the fiber scattering assembly 1, distinct and in addition to any upstream blend line components (such as described elsewhere herein), or the feed tower 3 may be one and the same as the storage vessel of a blend line. In embodiments herein comprising a load cell, the load cell 2 regulates the amount of a discharged fiber blend delivered by the feed tower 3 for laying down by the fiber scattering assembly. For example, the load cell 2 may be associated or interconnected with the feed tower 3 in such a manner to deliver a controlled amount of fiber blend to other components of the fiber scattering assembly 1 that discharge the fiber blend and lay down a composite layer. [0168] In the processes and systems herein, the fibers of each laid composite layer are substantially non-directional in arrangement. This non-directional orientation of fibers (or lack thereof) may be provided by an upstream blend line, the fiber scattering assembly, or a combination thereof.

[0169] The fiber scattering assembly 1 may be any fiber scattering assembly capable of scattering and/or laying down a fiber material, fiber blend, recyclable material, or any combination thereof. In certain embodiments, the fiber scattering assembly 1 may scatter and/or lay down any of the types of fibers disclosed herein, such as, but not limited to, non-melt fibers and/or thermal melt fibers or polymers. The fiber scattering assembly 1 may be a non-melt fiber scattering assembly (e.g. a bast fiber scattering assembly), a thermal melt fiber scattering assembly, a recyclable material fiber scattering assembly, or any other fiber scattering assembly capable of scattering or laying down a fiber blend. Each fiber scattering assembly 1 of the processes and systems herein may be the same or different than any other fiber scattering assembly 1 of the system or used in the process, depending on the type of fiber to be laid down in any particular layer.

[0170] In an embodiment, the processes or systems herein may comprise a fiber scattering assembly 1 comprising a load cell 2 that regulates the amount of a discharged fiber blend from the fiber scattering assembly 1. The discharged fiber blend is laid from the fiber scattering assembly 1 to form a composite layer. In an embodiment, the fibers of the composite layer are substantially non-directional in arrangement. In embodiments herein, one or more downstream fiber scattering assemblies 1 are positioned in sequence to receive the previously laid composite layer(s) from one of the upstream fiber scattering assemblies 1. In such embodiments, the previously laid composite layer(s) is used as a substrate for layering atop thereof each subsequent composite layer to provide a plurality of layers forming the multilayer composite.

[0171] In operation, each of the fiber scattering assemblies 1 of the processes and systems herein may be provided the same fiber blend or a different fiber blend than any other fiber scattering assembly 1 in the system or process. In an embodiment, each of the fiber scattering assemblies 1 is provided a different fiber blend. In an embodiment, each of the fiber scattering assemblies 1 is provided the same fiber blend. In an embodiment, two or more of the fiber scattering assemblies 1 are provided the same fiber blend, but at least one other is provided a different fiber blend. In an embodiment, the first and last fiber scattering assemblies 1 in sequence are provided the same fiber blend, and the fiber scattering assemblies positioned there between in sequence are provided a different fiber blend. Any different arrangement may be configured depending on the desired fiber makeup of each composite layer of the multilayer composite. [0172] In some embodiments where two or more of the fiber scattering assemblies 1 in the process or system are provided the same fiber blend, the fiber blend may be provided to the fiber scattering assemblies 1 either from the same upstream blend line or from different upstream blend lines. The blend line components and features thereof are described in more detail elsewhere herein. In some embodiments where two or more of the fiber scattering assemblies 1 in the process or system are provided the same fiber blend, the fiber scattering assemblies 1 may share the same feed tower 3 and then the fiber blend is provided to each load cell 2 of the different fiber scattering assemblies 1 from the same feed tower 2.

[0173] As described, a fiber blend comprising one or more fiber materials is provided to each of the fiber scattering assemblies 1. In some embodiments, the fiber blend is provided directly to the load cell 2, and the fiber scattering assembly may not include a feed tower 3. In some embodiments, the fiber blend is provided to a feed tower 3 which in turn provides the fiber blend to the load cell 2. A feed tower 3, as used herein, may comprise a storage chamber, a discharge apparatus, a belt for delivery of fiber to the load cell 2, or any combination thereof. The feed tower 3 of each fiber scattering assembly

1 may provide the fiber blend to the load cell 2 at any desired density or amount. For each fiber scattering assembly 1 in the processes or systems herein, the feed tower 3 may provide fiber blend to the load cell

2 at a density such that it is substantially equal or different than that of any other fiber scattering assembly 1 in the sequence. In other embodiments, the density and/or amount is controlled solely by or in combination with the load cell 2. Thus, each composite layer of the multilayer composite may have the same or different surface density as another. In certain embodiments herein, the use of two or more fiber scattering assemblies 1 to provide a multilayer composite may provide a lower tolerance on surface density or a lower variability in surface density, such that the tolerance or variability is less than about 10%, less than about 8%, less than about 6%, less than about 5%, less than about 4%, less than about 2% or less than about 1%.

[0174] Each feed tower 3 and/or load cell 2 may be independently controllable, such that each feed tower 3 and/or load cell 2 may provide a unique output, similar output or combination of unique and similar output to provide the multilayer composite. Output may comprise properties, such as, but not limited to, surface amount, density, weight, volume, speed, or any combination thereof.

[0175] In some embodiments described herein, the step of laying a web of the discharged fiber blend from the fiber scattering assembly 1 may comprise a discharged fiber that when laid is substantially non-directional in the composite layer. A person of skill in the art would appreciate that processes such as cross-lapping or carding result in composites with tensile strengths in the X direction and the Y direction that are not equal. Cross-lapping, as would be known to a person of skill in the art, refers to a process or method wherein ends or edges of a fiber or other material are overlapped and joined to produce a continuous surface, material, or layer. Carding, as would be know to a person of skill, refers to a process or method wherein fiber material is passed between moving surfaces containing a flexible material embedded with metal pins, which breaks up fiber clumps and aligns the individual fibers in parallel. As such, a person of skill would recognize that techniques, such as carding which produce parallel fibers, result in tensile strengths that are substantially different in the X direction and the Y direction. Advantageously, the processes and systems disclosed herein are capable of providing composite layers and multilayer composites having a non-directional arrangement of fibers, and thereby tensile strengths in the X direction and the Y direction that are substantially equal.

[0176] In certain embodiments herein, one or more layers of the multilayer composite disclosed herein may be formed using bast fiber. One of skill in the art would appreciate that creating a web, composite layer, or multilayer composite using only bast fibers would be impractical or not possible using carding. Having multiple layers, such as for example, a six layer multilayer composite, with non-oriented fiber directions allows for better tool fill out across the Z dimension surface, known as tool draft slippage during tool closing.

[0177] As described, the fiber scattering assembly 1 of the present disclosure comprises a load cell. The load cell 2 may be any suitable device or apparatus for regulating and/or controlling the quantity of fiber blend used by the fiber scattering assembly 1 for laying a composite layer. In an embodiment, the load cell 2 enables the fiber scattering assembly 1 to lay down a desired quantity of fiber blend, while retaining or providing a non-directional arrangement of fibers. In an embodiment, the load cell 2 comprises a feed chute, a belt, a weigh scale, a storage vessel, or any combination thereof. In an embodiment, one or more components of the load cell 2 are within an enclosed structure of the fiber scattering assembly 1 (see FIGs. 1-3). In an embodiment, the load cell 2 communicates with the PLC 4 to regulate the amount of fiber blend delivered from the feed tower 3. For example, in an embodiment, the load cell 2 may be or comprise a transducer or equivalent thereof, which converts force, such as, but not limited to tension, compression, pressure or torque into an electrical output, wherein the changes in force results in a proportional change in the electrical signal, which can then be used to regulate an upstream and/or downstream process. The load cell 2 may regulate the amount of a discharged fiber blend such that it is a desired amount, weight, density, or other property.

[0178] As shown in FIGs. 1-3, in an embodiment the load cell 2 is positioned below the feed tower 3 and is interconnected to a web forming device 5 of the fiber scattering assembly 1. In this embodiment, the load cell is within an enclosed structure. This is simply an exemplary configuration. In other embodiments, the load cell 2 may a component of or within the feed tower 3, a component of or within the web forming device 5, mounted atop or on the side of the web forming device 5, or any other configuration or combination thereof so long as the load cell 2 is of appropriate configuration to regulate delivery of the fiber blend from the fiber scattering assembly 1.

[0179] As shown in FIG. 4, in some embodiments, the load cell 2 may comprise an input feed chute 6, one or more input conveying belts 7 (7a and 7b), an input weigh scale 8, or any combination thereof. In certain embodiments, the input weigh scale 8 measures the weight of the fiber blend as it passes and adjusts the amount of the fiber blend delivered from the feed tower 3 to the load cell 2, thereby ultimately regulating the amount of fiber blend delivered to the web forming device 5. For example, the input weigh scale 8 may control the rotation speed of a distribution apparatus at the bottom of the feed tower 3, whereby a faster rotation increases the amount of fiber blend delivered and a slower rotation speed decreases the amount of fiber blend delivered. In certain embodiments, the input weigh scale 8 measures the weight of the fiber blend as it passes and adjusts the speed of the one or more belts downstream of the web forming device (e.g. output conveying belts and/or main line conveying belt), which are operationally associated with the fiber scattering assembly 1 and thereby ultimately regulate the amount of fiber blend that forms the composite layer at any given time (e.g. a faster belt speed would reduce the amount of fiber blend forming the composite layer, and vice versa). In an embodiment, the input weigh scale 8 is in communication with the PLC 4 for controlling these functions (e.g. for regulating the amount of the fiber blend delivered to the load cell from the feed tower and/or the speed of the one or more belts operationally associated with the two or more fiber scattering assemblies).

[0180] In an embodiment, the input weigh scale 8 is a continuous weigh scale that continually monitors and obtains the weight of the fiber blend as it passes. In an embodiment, the input weigh scale 8 is an automated intermittent weigh scale that monitors and obtains the weight of the fiber blend at predetermined intervals or times. In an embodiment, the input weigh scale 8 is a manually operated weigh scale that monitors and obtains the weight of the fiber blend in response to input by an operator. In an embodiment, the input weigh scale 8 may operate in any combination of these modes of operation (e.g. continuous, intermittent, or manual).

[0181] Traditional non-woven composites may be laid using a single load cell providing a heavy gram weight. Additionally, the use of a single load cell may result in imprecise laying and therefore result in a composite with a large tolerance on surface density, such as for example, equal to or greater than 10%. The use of two or more fiber scattering assemblies 1, each having an independent load cell 2, may therefore improve properties, such as for example, surface density tolerance, of the composite layers and/or multilayer composite.

[0182] In certain embodiments described herein, the fiber scattering assembly 1 comprises a web forming device 5 for laying down the discharged fiber blend to form the composite layer. In an embodiment, the web forming device 5 is any suitable device for randomly scattering the fiber blend in a consistent manner. In an embodiment, the web forming device 5 operates by collecting the fiber blend at discharge to form a final web of desired width and weight. In an embodiment, the web forming device 5 is a mini card web layer.

[0183] In certain embodiments described herein, a conveying belt receives the discharged fiber blend to provide a composite layer thereon. The conveying belt may be any suitable type of belt, including any belt as described herein. A person of skill in the art, in light of the teachings herein, would be able to select an appropriate conveying belt for a desired application. For the first fiber scattering assembly 1 in the sequence, the discharged fiber blend 9 may be laid either onto an output conveying belt 10 (see FIGs. 2 and 3) or directly onto the main line conveying belt 11 (not shown). For each downstream fiber scattering assembly 1 in the sequence, the discharged fiber blend may be laid directly onto an output conveying belt 9 which then transfers the composite layer to position it atop a previously laid composite layer on the main line conveyer belt 11 (see FIG. 5) or the discharged fiber blend may be laid directly onto the previously laid composite layer on the main line conveyer belt 11 (not shown). Various different configurations of the systems and belts may be employed. In some embodiments, there is only one output conveying belt 10 (see FIGs. 2-3). In some embodiments, there are two or more output conveying belts 10 (see e.g. FIG. 1, 10a and 10b; and FIG. 4, 10a, 10b and 10c). The speed of output conveying belts 10 may be adjusted to assist in regulating the quantity or density of the fiber blend in each composite layer.

[0184] In certain embodiments, the systems herein further comprise a degassing belt 12 for contacting the composite layer on an opposite side to that which contacts the conveying belts. The degassing belt 12 of the present disclosure has unique characteristics in regards to its configuration and operation so as to provide advantageous properties to the composite layer and multilayer composite. Firstly, passing the composite layer or multilayer composite between a conveying belt and the degassing belt 12 compresses the material and provides a degassed composite layer or multilayer composite. Secondly, and more uniquely, the configuration and operation of the degassing belt 12, in conjunction with a conveying belt, causes fibers within composite layer or multilayer composite to change from a vertical direction towards a horizontal direction. In other words, it causes fibers to change orientation from standing up within the composite layer (vertical) to laying down within the composite layer (horizontal). This is a significantly advantageous property in respect to establishing consistency and improvements in surface density quality, as well as influencing in-machine direction versus crossmachine direction strength.

[0185] FIGs. 1-4 include schematic drawings of exemplary embodiments of a system herein that comprises a degassing belt downstream of the fiber scattering assembly 1. In FIGs. 1 and 4, the degassing belt 12 is positioned above a horizontally aligned output conveying belt 10a positioned immediately adjacent the fiber scattering assembly 1. In FIG. 2, the degassing belt 12 is positioned above the main line conveying belt 11 immediately adjacent where the composite layer is transferred from the output conveying belt 10 onto the main line conveying belt 11. In FIG. 3, the degassing belt 12 is positioned above a sloped output conveying belt 10 that transfers the composite layer to the main line conveying belt 11. Several alternate placements of the degassing belt 12 are possible. In preferred embodiments, the degassing belt is placed above an output conveying belt 10 so that only the single composite layer is passed between the output conveying belt and the degassing belt, such as in FIGs. 1, 3 and 4).

[0186] As mentioned above, FIG. 2 depicts an embodiment in which the degassing belt 12 is positioned along a main line conveyer belt 11 used to carry and deliver the previously laid composite layer(s) to each subsequent fiber scattering assembly 1. In some embodiments of such configuration, degassing may only occur once after the last fiber scattering assembly 1 in the sequence. Alternatively, in other embodiments, degassing may occur at multiple instances along the sequence, such as for example after each fiber scattering assembly 1 or at desired intervals (e.g. after the 2 ^nd , 4 ^th , 6 ^th , etc. fiber scattering assembly 1). As will be appreciated, in the arrangement of FIG. 2, all previously laid composite layers are degassed as they pass the degassing belt 12.

[0187] In contrast, FIG. 1, 3 and 4 depict embodiments in which the degassing belt 12 is positioned on an output conveying belt 10 that has thereon only the single composite layer laid by the preceding fiber scattering assembly 1. In some embodiments of such configuration, degassing may occur after each fiber scattering assembly 1 in the sequence. Alternatively, in other embodiments, degassing may occur only after certain fiber scattering assemblies 1 if it is desired that only certain composite layers are degassed. As will be appreciated, the embodiments of FIGs. 1-4 may be combined so as to include degassing belts 12 at multiple instances and including on both the main line conveying belt 12 and a output conveying belt 10 that has thereon only the single composite layer laid by the preceding fiber scattering assembly 1. The passing of a composite layer or a multilayer composite between a conveying belt 10 and the degassing belt 12 provides a degassed composite layer and/or degassed multilayer composite.

[0188] As mentioned above, the degassing belt 12 of the present disclosure has unique characteristics in regards to its configuration and operation. In an embodiment, the degassing belt 7 operates at a different speed than the belt over which it is positioned (e.g. an output conveying belt 10). In some embodiments, the degassing belt 12 is at a faster speed than the output conveying belt 10 so as to drag and cause a regression on a bottom surface of the composite layer. In some embodiments, the degassing belt 12 is at a slower speed than the output conveying belt 10 so as to drag and cause a regression on a top surface of the composite layer. Preferably, the output conveying belt 10 operates at a predetermined line speed and the degassing belt 12 is manually or automatically set to a slower speed to cause fiber to change from a vertical direction towards a horizontal direction, depending on how far speed of the degassing belt 12 is regressed compared to the output conveying belt 10.

[0189] In an embodiment, the degassing belt 12 is oriented at an angle in relation to the belt over which it is positioned. In an embodiment, the degassing belt 12 is adjustable and/or pivotable at one or both of its upstream end 12a and its downstream end 12b. Many different mechanisms or modes of action may be used to adjust the angle of the degassing belt 12 in relation to the belt over which it resides. In an embodiment, an actuator 13 may be used to adjust the angle of the degassing belt 12. In an embodiment, such as shown in FIG. 2, the upstream end 12a of the degassing belt 12 is positioned closer to the belt over which it is positioned. In an embodiment, such as shown in FIG. 3, the downstream end 12b of the degassing belt 12 is positioned closer to the belt over which it is positioned. In a preferred embodiment, the degassing belt 12 is angled to form a V-shape into which the composite layer passes as it moves downstream. This configuration, with the downstream end 12b positioned closer to the conveying belt, may be advantageous in providing a staged progression to the most compressed configuration, allowing better degassing and more effective changes to the orientation of the fibers.

[0190] In an embodiment, the degree (0) of adjustment in angle of the degassing belt 12 from level with the conveying belt is +1°, +2°, +3°, +4°, +5°, +6°, +7°, +8°, +9°, or +10°, whereby a positive (+) degree indicates that the downstream end 12b is moved away from the conveying belt and/or the upstream end 12a is moved towards the conveying belt. In an embodiment, the degree (0) of adjustment in angle of the degassing belt 12 from level with the conveying belt is -1°, -2°, -3°, -4°, -5°, -6°, -7°, -8°, -9°, or -10°, whereby a negative (-) degree indicates that the downstream end 12b is moved towards the conveying belt and/or the upstream end 12a is moved away from the conveying belt. [0191] In an embodiment, in operation of the systems herein, the degassing belt 12 is angled with its downstream end 12b closer to the output conveying belt 10 over which it is positioned, and the degassing belt 12 is run at a slower speed than the output conveying belt 10.

[0192] A person of skill in the art, in light of the teachings herein, would be able to select appropriate output conveying belts 10, main line conveying belts 11, and degassing belts 12 for the degassing embodiments described herein.

[0193] As would be appreciated by the person of skill in the art, the composite layer or multilayer composites may not be of the desired final shape for any given product, for example in respect of shape, size, volume, or other property. Degassing may, for example, reduce the height of the composite layer or multilayer composite relative to its height prior to degassing, such as for example, by at least 5%, by at least 10%, by at least 15%, by at least 20%, by at least 25%, by at least 30% or more. As described, degassing may also align the fibers of the composite layer or multilayer composite, and aligned fibers may improve surface density of the resulting material.

[0194] As described, in certain embodiments herein each layer of the multilayer composite may be laid at unequal surface density weights, equal surface density weights or a combination of equal and unequal surface density weights. One of the benefits of off-balancing (different surface density weights) compared to an even balance (substantially equal surface density weight), is such that off-balanced fiber webs or composite layers may have a higher flexural modulus strength than fiber webs of the same material and the same final surface density. Having off-balanced fiber webs or composite layers may also result in a better forming product particularly when material is formed into a 3D shape.

[0195] In some embodiments of the processes and systems herein, the in sequence arrangement of the fiber scattering assemblies 1 may provide a uniform density across the production line to each composite layer and/or the multilayer composite. Each fiber scattering assembly 1 may provide a certain desired weight across all of the production line to ensure a substantially similar surface density across the width and length of each composite layer and, thereby, the multilayer composite. For example, the feed tower 3 may feed across a load cell 2 that may regulate the amount of discharged fiber blend according to the specifications of the desired multilayer composite.

[0196] As shown in FIG. 4, in some embodiments, the system disclosed herein may comprise an output weigh scale 14. The output weigh scale 14 maybe used to monitor the final set weight of the passing composite layer. In certain embodiments, the output weigh scale 14 measures the weight of the composite layer as it passes and adjusts the amount of the fiber blend delivered from the feed tower 3 to the load cell 2, thereby ultimately regulating the amount of fiber blend delivered to the web forming device 5. For example, the output weigh scale 14 may, optionally in coordination with the input weigh scale 8, control the rotation speed of a distribution apparatus at the bottom of the feed tower 3, whereby a faster rotation increases the amount of fiber blend delivered and a slower rotation speed decreases the amount of fiber blend delivered. In certain embodiments, the output weigh scale 14 measures the weight of the composite layer as it passes and adjusts the speed of the one or more belts upstream (e.g. output conveying belts), which are operationally associated with the fiber scattering assembly 1 and thereby ultimately regulate the amount of fiber blend that forms the composite layer at any given time (e.g. a faster belt speed would reduce the amount of fiber blend forming the composite layer, and vice versa).

[0197] For example, if it was desired to form a multilayer composite having six layers and a total weight of 1200 gsm, one embodiment would be for each layer in the multilayer composite to weigh 200 gsm. The inclusion of an output weigh scale 14 after each fiber scattering assembly can ensure, during operation, that each composite layer is produced according to required specification and, if not, appropriate adjustments can be advantageously be made on the fly. The calculation can also take into account any downstream losses during further processing. For example, if it were determined that a 10% loss in fibers occurs in downstream processing (e.g. dusting), the target weight at the output weigh scale 14 could be adjusted to 220 gsm to achieve a six layer composite with a total weight of 1200 gsm.

[0198] In an embodiment, the output weigh scale 14 is in communication with the PLC 4 for controlling these functions (e.g. for regulating the amount of the fiber blend delivered to the load cell from the feed tower and/or the speed of the one or more belts operationally associated with the two or more fiber scattering assemblies).

[0199] In an embodiment, the output weigh scale 8 is a continuous weigh scale that continually monitors and obtains the weight of the composite layer as it passes. In an embodiment, the output weigh scale 14 is an automated intermittent weigh scale that monitors and obtains the weight of the composite layer at predetermined intervals or times. In an embodiment, the output weigh scale 14 is a manually operated weigh scale that monitors and obtains the weight of the composite layer in response to input by an operator. In an embodiment, the input weigh scale 14 may operate in any combination of these modes of operation (e.g. continuous, intermittent, or manual).

[0200] As used herein, the term “programmable logic controller” (PLC) 4 may comprise any suitable components to monitor and/or control the functioning of various components of the fiber scattering assembly 1. In an embodiment, the PLC 4 comprises a computer control system that monitors the state of input devices, such as for example, a load cell 2, an input weigh scale 8 and/or an output weight scale 14, and make decisions, based on a custom program to control the output, such as for example, weight of a discharged fiber blend. Each fiber scattering assembly 1 may have its own PLC 4 for independent functioning thereof, or two or more, or all, of the fiber scattering assemblies 1 may use the same PLC 4 for coordinated functioning thereof.

[0201] It is contemplated that in certain embodiments, the fiber scattering assembly 1 may comprise two load cells. For example, the fiber scattering assembly 1 may comprise an input load cell that may regulate an amount of fiber blend discharged from the feed tower 3 to other components of the fiber scattering assembly 1 and an output load cell that may regulate an amount of fiber blend laid down by these components into the composite layer. In certain embodiments, the input and output load cells may be in communication, through for example the PLC 4, to regulate the amount of the fiber blend at different points within the fiber scattering assembly 1. As the amount of a fiber blend discharged and the amount of a fiber blend laid may be different under certain conditions or circumstances, it may be advantageous to regulate the fiber blend at two distinct steps to ensure the desired output in the composite layer. The use of two load cells may provide increased accuracy in discharging the desired amount of fiber blend, compared to use of a single load cell. In certain embodiments, one or more of the fiber scattering assemblies 1 in the system or used in the process may comprise two load cells. In certain embodiments, the recycler assembly may comprise two load cells.

[0202] In some embodiments, the systems herein may further comprise a density scanner 15, such as a surface density scanner. The density scanner 15 may be configured for continuous, intermittent (automated), or manual operation to take weight calculations cross-machine direction and/or in-machine direction. In an embodiment, the density scanner 15 may have one or both of a visual live screen result display and a storage device capable of recording weights by lot that can be used for record keeping purposes. In an embodiment, the density scanner 15 may be positioned at the downstream end of the series of fiber scattering assemblies 1. In another embodiment, one or more density scanners 15 may be interspersed along the series of fiber scattering assemblies 1, for example after each fiber scattering assembly, after every second fiber scattering assembly, or any other configuration. In an embodiment, the density scanners 15 are a component of the fiber scattering assemblies.

[0203] As used herein, a “density scanner” 15 may refer to any type of scanner that is capable of measuring the density of a single composite layer or multiple composite layers, including in some embodiments the entire multilayer composite. In certain embodiments, the density scanner 15 may communicate with one or more of the fiber scattering assemblies 1 (e.g. in a feedback loop) to regulate and adjust the amount of fiber blend being discharged from each of the fiber scattering assemblies 1. In certain embodiments, the density scanner 15 may scan the density of the one or more composite layers in small regions, such as for example, about every 10-50 mm, or more or less. In certain embodiments, the density scanner 15 may scan in a direction perpendicular (cross-direction) to that of the movement of the composite layer or multilayer composite on a conveying belt or in the same direction (in-direction) as movement of the composite layer or multilayer composite on a conveying belt. In response to variations in the desired density of the composite layer or multilayer composite, the density scanner 15 may communicate with one or more of the fiber scattering assemblies 1 to alter its or their output parameters, such as flow rate, to provide the desired density. The desired density may vary depending on the fiber types, the fiber blends and/or the desired product.

[0204] In certain embodiments, the density scanner 15 may be operatively linked to a computing system or computer processor such that the density of unique composite layers and/or multilayer composites is learned by the computing system or computer processor through an appropriate artificial intelligence (Al) technology or algorithm, such as for example machine learning, to provide information regarding each unique blend, which may then be used to uniquely regulate one or more fiber scatter assemblies 1 or recycler assembly 6. In certain embodiments, the density scanner 15 may be programmed to measure the density of a composite layer or multilayer composite and identify the fiber composition of said composite layer or multilayer composite. In certain embodiments, the density scanner 15 may use pre-programmed information regarding the desired fiber density for each unique fiber blend, such that it provides distinct regulatory parameters, such as density or flow rate, for each unique desired output. In certain embodiments, one or more fiber scattering assembly 1 in the system or used in the process may comprise a density scanner 15. In certain embodiments, all the fiber scattering assemblies in the system or used in the process may comprise a density scanner 15. In certain embodiments, one fiber scattering assembly may comprise a density scanner 15. In certain further embodiments, the one fiber scattering assembly comprising a density scanner 15 may be the last or final fiber scattering assembly in the system or used in the process. In certain embodiments, the density scanner 15 is a separate component from the fiber scattering assembly and is located downstream of the series of the fiber scattering assemblies (see e.g. Fig. 9).

[0205] The technology of the present disclosure may be suitable to provide many different multilayer composites, which may, for example, comprise different fiber blends, different fiber materials and/or different numbers of layers, including some layers optionally comprising a recycled feed material. With reference to the drawings herein, the present disclosure largely discusses the technology in the context of two, six and seven layer composites, but it will be appreciated that other applications and uses are equally applicable. In an embodiment, there are two, three, four, five, six, seven, or more fiber scattering assemblies in sequence in the systems herein. In an embodiment, there are two, four, six or eight fiber scattering assemblies in sequence in the systems herein.

[0206] FIGs. 5-8 are schematic drawings of exemplary embodiments of different arrangements of systems of the present disclosure. FIG. 5 depicts a system comprising two fiber scattering assemblies 1, with one fiber scattering assembly lb downstream of the other to receive a previously laid composite layer 16 from the upstream fiber scattering assembly la via the one or more output conveying belts 10 and the main line conveying belt 11. The system comprises an upstream fiber scattering assembly la for laying a discharged fiber blend onto the output conveying belt 10a as a composite layer, which is then passed through the degassing belt 13 and onto another output conveying belt 10b to be delivered to the main line conveying belt 11. On the main line conveying belt 11 the composite layer is delivered to the downstream fiber scattering assembly 1 as a previously laid composite layer, where another composite layer is placed atop the previously laid composite layer. As will be appreciated by the disclosure herein, the systems and processes may include any number of fiber scattering assemblies 1 to provide multilayer composites having different numbers of composite layers. Also, the fiber scattering assemblies 1 may be any of those described and encompassed by the present disclosure, and each fiber scattering assembly 1 in the system may be the same or different than any other.

[0207] FIG. 6 depicts an embodiment of a system herein comprising six of the fiber scattering assemblies 1 (see la-lf). In operation, the earliest fiber scattering assembly la in the sequence lays a first composite layer, which is delivered to each subsequent fiber scattering assembly Ib-lf by way of the output conveying belts 10 and the main line conveying belt 11 to lay atop thereof each additional composite layer and thereby provide a multilayer composite having six layers. For simplicity, features such as the input weigh scale 8, degassing belt 13, and output weigh scale 12 are not shown in FIG. 6, but these may optionally be included for the advantageous reasons described herein. Again, as will be appreciated by the disclosure herein, the systems and processes may include any number of fiber scattering assemblies 1 to provide multilayer composites having different numbers of composite layers. In an embodiment, the system comprises two, three, four, five, six, seven, or more fiber scattering assemblies 1. Also, the fiber scattering assemblies 1 may be any of those described and encompassed by the present disclosure, and each fiber scattering assembly 1 in the system may be the same or different than any other. [0208] FIG. 7 depicts an alternate embodiment of a system herein comprising six of the fiber scattering assemblies 1 (see la-lf), with a recycler assembly 17 positioned between two of the fiber scattering assemblies 1 (between 1c and Id). In operation, the earliest fiber scattering assembly la in the sequence lays a first composite layer, which is delivered to the next two fiber scattering assemblies lb and 1c by way of the output conveying belts 10 and the main line conveying belt 11 to lay atop thereof additional composite layers. The three-layer composite is then delivered to the recycler assembly 17 by way of the main line conveying belt 11 to receive a composite layer comprising a recycled feed material. The multilayer composite then continues down the sequence on the main line conveyer belt 11 to three additional fiber scattering assemblies 1 to each add an additional composite layer and thereby provide a seven-layer composite with a layer of recycled feed material in the middle. As will be appreciated, the recycler assembly 17 may be positioned at any one or more positions along the sequence, and there may be any number of fiber scattering assemblies 1 before, after or between recycler assemblies 17.

[0209] In certain embodiments, a plurality of fiber scattering assemblies 1 may be arranged in sequence to produce a multilayer composite, such as for example, five fiber scattering assemblies, six fiber scattering assemblies, seven fiber scattering assemblies, or more. In certain embodiments, each of the fiber scattering assemblies 1 in the plurality provide a composite layer of a different fiber blend, the same fiber blend, or any combination of different and same fiber blends. In some embodiments, each of the fiber scattering assemblies 1 in the plurality may lay down the fiber blend in a composite layer at a different surface density, a substantially equal surface density, or a combination of different and substantially equal surface densities.

[0210] The plurality of fiber scattering assemblies 1 may be used to prepare the multilayer composite. The use of a plurality of fiber scattering assemblies 1 may result in a decreased variation in output of the fiber blend, such as for example surface density, such that the resultant multilayer composite may have a substantially improved tolerance on surface density, such as for example, a decrease from about 10% for traditional one load cell systems to about 2% for an embodiment disclosed herein.

[0211] In some embodiments of the systems and processes herein, a recycler assembly 17 may be in place of one or more of the fiber scattering assemblies 1, the recycler assembly 17 for receiving a recycled feed material comprising a recycled trim waste, an end of life material, or any combination thereof, and laying a recycled feed material layer. The recycler assembly 17 may be a separate and distinct component of the systems herein that operates absent feed of a fiber blend as described herein, or the recycler assembly may be or comprise a variation of a fiber scattering assembly 1 herein such that the recycled feed material is mixed with a fiber blend for incorporation into the multilayer composite. In certain embodiments, the recycler assembly 17 may comprise a fiber scattering assembly 1. In certain embodiments, the recycler assembly 17 may comprise one or more features of a fiber scattering assembly, and further comprise one or more of the following: one or more feed rolls, one or more wire openers, and one or more rotary brushes. In certain embodiments, the rotary brush may remove fiber or fiber blend from a wire opener. In certain embodiments, the material in the recycler assembly 17 may be a granulate.

[0212] As depicted in FIG. 7, the recycler assembly 17 may be positioned in the middle of the assembly line, such that an equal number of fiber scattering assemblies 1 are before and after the recycler assembly 17 in the series of assemblies, such as for example, three fiber scattering assemblies followed by a recycler assembly followed by three additional fiber scattering assemblies. As would be known to one skilled in the art, positioning of the assemblies may refer to both the spatial organization of the fiber scattering assemblies and/or the order in which they are used in embodiments described herein. For example, the middle fiber scattering assembly 1 may be spatially positioned as such, and/or used in the middle of the sequence to prepare the multilayer composite. It is also contemplated, but not depicted in FIG. 7, that the recycler assembly 17 may be positioned at any position within the series of fiber scattering assemblies 1. In some embodiments, the recycler assembly 17 may receive a portion of an end of life material, recycled or recyclable material, a recycled feed material, or any combination thereof.

[0213] The multilayer composite may comprise any suitable number of layers comprising recycled feed material. In an embodiment, the multilayer composite has a single layer comprising recycled feed material. In an embodiment, the multilayer composite has two, three, four, five, six, seven, or more layers comprising recycled feed material. In an embodiment, the total amount of recycled feed material by weight in the multilayer composite is between about 0.01% and about 10%, more particularly between about 0.1% and about 5%, and more particularly still between about 1% and about 5%. In an embodiment, the In an embodiment, the total amount of recycled feed material by weight in the multilayer composite is about 0.01%, about 0.025%, about 0.05%, about 0.075%, about 0.1%, about 0.25%, about 0.5%, about 0.75%, about 1.0%, about 1.5%, about 2.0%, about 2.5%, about 3.0%, about 3.5%, about 4.0%, about 4.5%, or about 5.0%. In an embodiment, the total amount of recycled feed material by weight in the multilayer composite is less than 5%. In an embodiment, the recycled feed material is a recycled trim waste (e.g. removed by an edge trimmer during prior runs of the system herein to produce a multilayer composite). In an embodiment, the recycled feed material is an end of life material. Thus, advantageously, recycled feed material can be re -processed back into a new article by using the systems and processes of the present disclosure, without impacting the performance of the new multilayer composite and while retaining carbon sequestered with the new multilayer composite.

[0214] FIG. 8 is a top view of the system depicted in FIG. 7. As shown in FIG. 8, in an embodiment of the systems herein, the blend line feed tower 18 alternates between opposite sides of the fiber scattering assembly 1 for each successive fiber scattering assembly 1 in the sequence. Thus, the first, third and fifth fiber scattering assemblies la, 1c and le have the blend line feed tower 18 positioned on the left side when looking downstream at the assembly line, whereas the second, fourth and sixth fiber scattering assemblies lb, Id and If have the blend line feed tower 18 positioned on the right side when looking downstream at the assembly line. Advantageously, arranging the blend line feed towers 18 in this alternating arrangement improves surface density consistency in the composite layers, and the multilayer composite as a whole, since imbalances in fiber scattering are obviated by directing the feed from opposite directions for each successive layering.

[0215] FIG. 9 is a schematic drawing of an exemplary system disclosed herein showing embodiments of certain downstream components from the final fiber scattering assembly 1 in the sequence. As shown, downstream of the fiber scattering assembly 1, there may be an edge trimmer 19, an end-line degassing apparatus 20, a loom 21, a line speed tension control device 22, a density scanner 15, a foam injection applicator 23 comprising staggered drive heads above and below conveying belt; and a radio frequency generator 24.

[0216] In the processes and systems herein, an edge trimmer 19 may be used to set the multilayer composite to a desired width and/or to ensure that any edge weight discrepancies are removed before the multilayer composite is delivered downstream to the loom 21.

[0217] In the processes and systems herein, an end-line degassing apparatus 20 may be used to degas the multilayer composite and/or reduce the height of the multilayer composite. Although the end-line degassing apparatus 20 may be a belt, its configuration and operation is different than the degassing belt 12 described earlier. For one, the end-line degassing apparatus 20 contacts the composite layer or multilayer composite at a different angle. In an embodiment, the lengthwise orientation of the end-line degassing apparatus 20 is at an angle of between about 25 degrees and about 80 degrees relative to the main line conveying belt 11. In an embodiment, the lengthwise orientation of the end-line degassing apparatus 20 is at an angle of about 25 degrees, about 30 degrees, about 35 degrees, about 40 degrees, about 45 degrees, about 50 degrees, about 55 degrees, about 60 degrees, about 65 degrees, about 70 degrees, about 75 degrees, or about 80 degrees relative to the main line conveying belt 11. In a particular embodiment, the lengthwise orientation of the end-line degassing apparatus 20 is at an angle of about 50 degrees relative to the main line conveying belt 11. In contrast to the degassing belt 12, the an end-line degassing apparatus 20 operates at substantially the same speed as the main line conveying belt 11 to avoid any distortion between the layers of the multilayer composite.

[0218] In the processes and systems herein, a loom 21 may be used to provide any number of different functions. For example, in an embodiment, a loom 21 may be used for amalgamating individual fibers in the multilayer composite. As used herein, the term “amalgamated”, “amalgamate” or “amalgamating” may refer to intertwining, combining, organizing, or other appropriate terms known by a person of skill in the art. A person of skill in the art, in light of the teachings herein, would be able to select an appropriate loom 21 for a given system or process herein. In an embodiment, the loom 21 is positioned within a sound-deadening cabinet, room or enclosure.

[0219] In an embodiment, the loom 21 may be a needle punch loom (e.g. a duo board hyper punch needle loom) and may be used to inner tangle the fibers of one or more composite layers. For example, the needle punch loom may be used to puncture composite layer(s) to provide in-direction tensile strength to allow the material to more effectively receive liquid or foam resin. As would be known to a person of skill in the art, a needle punch loom may use an elliptical beam drive in which the needle does not hinder the material movement during penetration but the needle moves horizontally in the material flow direction, resulting in less draft within the needlefelt and improved homogeneity and surface quality. A needle punch loom, such as a hyper punch needle loom, may limit the generation of heat thereby eliminating the release of vegetable fatty acids. The reduced needle friction may significantly extend the length of time in which a single needle can be used when compared to the use of a conventional needle looms, resulting in a decrease production cost and decrease in maintenance of the system or apparatus. The person of skill would be able to select an appropriate needle punch loom for the appropriate application.

[0220] Accordingly, in the systems and processes herein, a loom 21 may be employed for amalgamating individual fibers in the multilayer composite to provide in-direction tensile strength, to intertwine fibers within or between composite layers, and/or to receive one or more resins. A person of skill in the art, in light of the teachings herein, would appreciate that it is not possible or extremely difficult to inject resin into loose fiber or fibers with insufficient tensile strength that are generated using traditional techniques. Increasing tensile strength with, for example, a hyper punch needle loom, may provide structure that holds the fiber matrix together to receive resin. In certain embodiments, resin may not be applied to any layer. In certain embodiments, resin may be applied to one or more layers of the multilayer composite. It is contemplated that, in certain embodiments, the foam injection applicator may be configured such that resin is injected to a single designated layer or a plurality of designated layers. In certain embodiments, resin may be applied to one or more layers or the entire multilayer composite.

[0221] In the processes and systems herein, a line speed tension control device 22 may be used to control the speed of one or more belts within the system. In an embodiment, the line speed tension control device 22 modulates at least the speed of the main line conveying belt 11. In an embodiment, the line speed tension control device 22 modulates the speed of the output conveying belts 10 and main line conveying belt 11. In an embodiment, the line speed tension control device 22 modulates the speed of the input conveying belts 7, output conveying belts 10, and main line conveying belt 11. In an embodiment, speed adjustment by the line speed tension control device 22 is based on weight measurements taken by one or both of the input weigh scale 8 and the output weigh scale 14, operational via communication with the PLC 4.

[0222] In the processes and systems herein, a web accumulator (not shown) may be used to allow for continued operation of the system during a roll change out or pallet change out. In an embodiment, the web accumulator has enough storage capacity for at least 5 minutes, at least 10 minutes, at least 15 minutes, or more of downstream line stop. In an embodiment, the systems herein further comprise an emergency web cutter (not shown). If the system should stop for any reason, the downstream portion of the line (e.g. radio frequency generator 24, twin belt compression line, etc.) will continue to operate under battery power until the oven and twin belt compression lines have been product evacuated to prevent fire and/or damage.

[0223] In the processes and systems herein, a foam injection applicator 23 may be used to provide (e.g. infuse or impregnate) resin at one or both sides of the multilayer composite. In an embodiment, the foam injection applicator 23 may have heads that are purposefully staggered. In an embodiment, the foam injection applicator 23 provides resin at one side of the multilayer composite. In an embodiment, the foam inj ection applicator 23 provides resin at both sides of the multilayer composite.

[0224] In certain embodiments herein, the foam injection applicator 23 may comprise a liquid resin blending system for blending one or more resins, and/or a foam generation system, for generating foam resin from liquid resin. The foam injection applicator 23 may apply foam impregnation or inject foam from one or both sides of the multilayer composite. When from both sides, the injection of infusion of the resin on each side may be at the same time (i.e. simultaneously), at overlapping times, or sequentially. When foam is injected from both sides, the foam injection edge may meet in the middle of the multilayer composite, and may provide a full wet-out of the fibers within the multilayer composite, wherein full wet-out of the fiber may maximize fiber-to-fiber bonding and may improve mechanical performance by weight in the product. In an embodiment, foam is first infused from one side to impregnate resin about 60% of the thickness of the multilayer composite, then foam is infused from the opposite side to push foam back to center ending in a complete resin wet out of all fibers at an equal rate.

[0225] In certain embodiments, the foam resin may be a low density foam. In certain embodiments described herein, the foam resin have a density ranging between about 85 g/L and about 250 g/L. In certain embodiments, the density of the foam resin may vary depending on the surface density of material and the speed of line. A person of skill in the art, in light of the teachings herein, would be able to select an appropriate density of foam resin for a given application.

[0226] In an embodiment, the systems herein comprise a foam generator (not shown) for producing the foam to be used by the foam injection applicator 23. The foam generator may be any suitable apparatus or device. In an embodiment, the foam generator uses various pumps (e.g. PLC pumps) to combine desired liquid resins and create the liquid resin blends, including adding water when necessary. The liquid resin blends may then be fed or delivered (e.g. by pipes, tubes, or other conduits) into a continuous low/high speed mixing drum which mixes the liquid resin blend into a dense foam. In an embodiment, compressed air is used to achieve the correct foam density (e.g. between about 85 g/L and about 250 g/L).

[0227] As described in embodiments herein, foam injection applicator 23 may comprise staggered heads (e.g. drive heads). The heads of the foam injection applicator 23 may be staggered to allow acceleration of a second belt drive series to accommodate the linear length growth of the infused composite layer caused from absorbing liquids during first side injection. In certain embodiments, the linear length growth may be between about 0.1% and about 1%. A person of skill in the art, in light of the teachings herein, would be able to select appropriate heads for the staggered heads of the foam injection application.

[0228] In an embodiment, the foam injection applicator 23 is for infusing one or more resins into the amalgamated individual fibers of the multilayer composite.

[0229] In the processes and systems herein, one or more radio frequency generators 24 may be used for applying radio waves for removing liquid from the multilayer composite. A radio frequency generator is also known as a radio frequency drying over. A person of skill in the art, in light of the teachings herein, would appreciate that in order to thermally heat and compress a non-woven multilayer composite into a consolidated hard sheet, excess moisture in natural fiber, as well as added moisture contained in foam resin injection may need to be removed. In certain embodiments, liquid may be removed using radio frequency waves from a radio frequency generator 24, wherein radio frequency waves represent a measurement of the oscillation rate of the electromagnetic radiation spectrum with frequencies ranging from 300 gigahertz to 9 kilohertz. Radio frequency only absorbs energy if water or liquid is present and therefore any heat in a composite may only be residual heat from the vaporizing water or liquid, as the radio frequency waves will not heat dry material. A person of skill in the art, in light of the teachings herein, would be able to select an appropriate radio frequency wave generator 24 for the appropriate application.

[0230] In an embodiment, the systems herein comprise more than one radio frequency generator 24. In an embodiment, the system herein comprises two, three, four, five, or more radio frequency generators 24 in sequence. In an embodiment, the system herein comprises five radio frequency generators 24 or a five zone radio frequency generator 24. In an embodiment, each radio frequency generator or each zone thereof is wattage controlled to allow progressive increases in Kw input in the downstream direction. Normally, since the first radio frequency generator or zone encounters the multilayer composite in its wettest form, this first radio frequency generator or zone is run at lower Kw (e.g. lower than 30 Kw) to prevent overheating and bubbling of the infused resin due to high gas production. In an embodiment, each radio frequency generator or zone has independent wattage control and moisture content monitoring.

[0231] In the processes and systems herein, a heat compression apparatus may be used to consolidate the composite layers of the multilayer composite into a more compressed material. Any suitable form of a heat compression apparatus for heating, compressing and cooling the multilayer composite of the present disclosure into product sheets may be used. In an embodiment, the heat compression apparatus is a twin belt compression line (not shown). Typically, in the context of the systems and processes of the present application, the heat compression apparatus would be located near the end of the assembly line, for example downstream of any combination of the following components: the edge trimmer 19, the end-line degassing apparatus 20, the loom 21, the line speed tension control device 22, the density scanner 15, and the foam injection applicator 23 (if these components are present in the system).

[0232] In an embodiment, the twin belt compression line uses hot oil as a primary heat source to consolidate matrix of the multilayer composite and/or individual composite layers thereof. In this regard, the twin belt compression line may comprise a boiler to produce the hot oil. A hot oil pump (e.g. skid mounted) may then be used to deliver the hot oil to line manifolds in the heat zones sections of the twin belt compression line. The hot oil may be any suitable temperature, and in an embodiment is between about 100°C and about 325°C, more particularly between about 175°C and about 275°C, and more particularly still between about 200°C and about 250°C. In an embodiment, the cooling zones use a closed-loop glycol chilling to remove heat from the multilayer composite as it passes. In this regard, the twin belt compression line may comprise a chiller compressor.

[0233] The twin belt compression line may comprise one or more heating zones and one or more cooling zones. In an embodiment, all of the heating zones are located upstream of the cooling zones. There may be any number of heating and cooling zones, whereby each is a different temperature and/or compression setting than the previous zone. In each zone of the twin belt compression line, the multilayer composite is passed between two belts. In an embodiment, the twin belt compression line comprises one, two, three, four, five, six, seven, eight, nine, ten, or more heating zones. In an embodiment, the twin belt compression line comprises one, two, three, four, five, six, seven, eight, nine, ten, or more cooling zones. In an embodiment, each of the heating and cooling zones may independently be about Im, 2m, 3m, 4m, 5m, 6m, 7m, 8m, 9m, 10m or more in length.

[0234] Aa advantageous configuration for a twin belt compression line to be used in conjunction with the systems and processes herein may include: (i) four heating zones, each heating zone of about 2m in length; and three cooling zones, each cooling zone of about 2m in length; or (ii) eight heating zones, each heating zone of about 2m in length; and three cooling zones, each cooling zone of about 2m in length. As the skilled person will appreciate, many alternate configurations of the twin belt compression line are possible and may be used. The configuration of the twin belt compression line may be dependent upon the composition of each of the composite layers within the multilayer composite and/or the composition of the multilayer composite as a whole.

[0235] In an embodiment, each heating and cooling zone of the twin belt compression line is equipped with its own temperature and surface density control to allow variability in heat intensity as well as compression to set appropriate levels of heat to compression loading to optimize thermal conductivity. Throughout the twin zone compression belt line, belt contact is typically maintained on both sides of the multilayer composite as it passes through the heating and cooling zones. This may be particularly important in the cooling zones to maximize the removal of heat and to stabilize the product prior to exiting the twin belt compression line. [0236] In the processes and systems herein, an edge trim apparatus and/or a cross-cut apparatus may be positioned downstream of the heat compression apparatus. The edge trim apparatus makes final adjustments to the size of the multilayer composite sheet. In an embodiment, removed edge trim may be sent to receiver tanks. Different receiver tanks may be used for different multilayer composites produced by the system herein. For example, if the multilayer composite had been heat consolidated on the twin belt compression line, the edge trim may be re -ground and sent to a receiving tank for re-introduction into subsequently manufactured multilayer composites as a recycled feed material. If the multilayer composite has not been heat consolidated, it may not be necessary to re-grind the material and instead the fibers may be reopened and then used as recycled feed material (e.g. similar to trim waste received from edge trimmer 19). In both, rather than valuable fiber material being lost/discarded, it is capable of being recycled and used in subsequently manufactured multilayer composites in accordance with the system and processes disclosed herein.

[0237] The cross-cut apparatus may be used to convert product from a continuous sheet into cut lengths of sheets. Alternatively, longer lengths may be cut and the lengths of material rolled into rolls of multilayer composite sheet.

[0238] In an embodiment, at the end of the assembly line a palletizer stacks sheets of cuts multilayer composite (e.g. up to 150 sheets) on a skid automatically. When skid is full may be discharged via a pallet belt to a pallet pick up area. A new pallet is moved into place as the full pallet exits. Once the new pallet is in place, the skid is elevated to a predetermined height and the stacking of new cuts of multilayer composite begins. During the pallet transfer, a stacking system may store cut sheets and then, once the new pallet is positioned, the stored sheets are placed on pallet and cycle repeats.

[0239] In an embodiment, the end of line contains an autonomous self-loading coiling system comprising a winder for loading the multilayer composite on a roll. The winder may be a self-loading, self-rolling and self-discharging system. Once end of the multilayer composite is loaded on roll, the roll is transferred to a plastic wrap transfer conveyor. Each roll may be auto-wrapped with plastic to protect the surface from foreign contamination. After the roll is wrapped, it may be self-delivered to a pickup area.

[0240] As the skilled person will appreciate, there are many different arrangements and configurations of these downstream components (the edge trimmer 19, the end-line degassing apparatus 20, the loom 21, the line speed tension control device 22, the density scanner 15, the foam injection applicator 23, and the heat compression apparatus) that may be used in the systems herein. In an embodiment, all of these components may be included in a single system of the present disclosure to form a single assembly line. In other embodiments, any one or more of the components may not be used in the single assembly line. For example, if the multilayer composite is comprised of a sufficient amount of thermal melt fibers, it may not be necessary to include the loom 21 and/or the foam injection applicator 23 as heat and compression from the heat compression apparatus may be sufficient to transform the multilayer composite into a final product. In other embodiments, such as if the multilayer composite is comprised of a substantial quantity of non-melt fibers, it may not be necessary to include the heat compression apparatus. As described herein, individual layers of the multilayer composite may be of different types (e.g. thermal set versus thermal melt layers). The ability to combine and/or mismatch thermal set layers and thermal melt layers within a single multilayer composite is an advantageous property of the systems and processes herein. The skilled person, having regard to the present disclosure, could select appropriate downstream processing equipment and steps based on the types of layers included in the multilayer composite. Moreover, although all of the components of the system disclosed herein may be configured as a single assembly line, it is also possible that they contained in different assembly lines, either within the same building or facility, or at different locations.

[0241] FIG. 10 is a schematic drawing of an exemplary system disclosed herein showing embodiments of certain upstream components for providing the fiber blend to the fiber scattering assemblies 1. As shown, in some embodiments of systems and processes herein, there is positioned upstream one or more debalers 25, one or more debaler belts 26, and a blend line assembly 27. In some embodiments, the blend line assembly 27 includes in sequence a debaler belt 28, a rotating wire cylinder 29, an air tube 30, a storage vessel 31, a blend line fiber opener 32, and a fiber blend transfer fan 33. Downstream of the blend line assembly 27 there may be a fiber blend delivery tube 34 that transfers the fiber blend either to the blend line feed tower 18 or to a feed tower of the fiber scattering assemblies 1. The fiber blend may be moved through any portion of the upstream processing by being pneumatically conveyed, mechanically conveyed, or any combination thereof. When pneumatically conveyed, it may be done under vacuum, without vacuum, by transfer fan, or any combination thereof. When mechanically conveyed, it may be by a belt as described elsewhere herein, by an auger, or any combination thereof. In certain embodiments, each debaler 25 may provide a fiber material to a single blend line assembly 27 or to a plurality of blend line assemblies 27. In certain embodiments, a pair of debalers 25 may provide a fiber material to a single blend line assembly 27. It is contemplated that each debaler 25 may comprise a unique fiber that is not in any other debaler 25, the same fiber as another debaler 25, or any combination of fibers relative to the other debaler(s) 25 in the system or to perform the process. Each debaler 25 may receive a processed fiber material, such as a compressed bale of fiber, and break the processed fiber material to provide the fiber material. In certain embodiments, the steps of debaling and blending may be performed separately or simultaneously. In light of the teachings herein, a person of skill in the art would be able to select an appropriate debaler(s) 25 for a given embodiment as disclosed herein.

[0242] In certain embodiments, each debater 25 and blend line assembly 27 may provide fiber material (fiber blend) to a single fiber scattering assembly 1. In certain embodiments, each debater 25 and blend line assembly 27 may provide fiber material (fiber blend) to two or more fiber scattering assemblies 1. In certain embodiments, two or more debaters 25 provide fiber material to a single blend line assembly to prepare the fiber blend. The two or more debalers 25 may each process a different type of fiber or the same type of fiber, typically a different type of fiber.

[0243] In certain embodiments, with each of the fiber scattering assemblies 1 there is a separate and independent assembly of the one or more debalers 25 and the blend line assembly 27. In certain embodiments, with each if the fiber scattering assemblies 1 there is a pair of separate, and optionally independent debalers 25, and a single the blend line assembly 27.

[0244] In certain embodiments, in operation, each of the separate and independent assemblies of the one or more debalers 25 and the blend line assembly 27 may provide a different fiber blend to each of the fiber scattering assemblies 1. In certain embodiments, in operation two or more of the separate and independent assemblies of the one or more debalers 25 and the blend line assembly 27 may provide the same fiber blend to two or more of the fiber scattering assemblies 1. In certain embodiments, the fiber may be processed to an average length of about 10 mm to 50 mm. In certain further embodiments, the fiber may be processed to an average length of about 30 mm. In certain embodiments, vascular bundles of fiber may be reduced. In certain embodiments, vascular bundles may be reduced to less than 10 individualized fibers per bundle. In certain embodiments, vascular bundles may be reduced to less than 3 individualized fibers per bundle. A person of skill in the art would recognize that traditional systems and processes to prepare non-woven composite require longer fibers up to 90 mm to run, and the use of longer fibers in traditional systems results in significant fiber fall out.

[0245] As shown in FIG. 10, the upstream components (i.e. upstream of the fiber scattering assemblies 1) may comprise a single debaler 25, the debaler belt 26 and the blend assembly 27. In such embodiments, the debaler 25 may be used to process a single fiber material or two or more different fiber materials to supply the fiber scattering assembly 1 with a fiber blend. From the blend line assembly 27, the fiber blend may be provided directly to the feed tower 3 of the one or more fiber scattering assemblies 1 or to a blend line feed tower 18 whereby the blend line feed tower 18 stores the fiber blend until it is needed and transferred to the one or more fiber scattering assemblies 1. In an embodiment, a single assembly line of the upstream components of FIG. 10 delivers fiber blend to a single fiber scattering assembly 1 (directly or via a blend line feed tower 18). In an embodiment, a single assembly line of the upstream components of FIG. 10 delivers fiber blend to two fiber scattering assemblies 1 (directly or via a blend line feed tower 18), for example two fiber scattering assemblies 1 that receive fiber blend from the same side. In an embodiment, a single assembly line of the upstream components of FIG. 10 delivers fiber blend to three of more fiber scattering assemblies 1 (directly or via a blend line feed tower 18), for example fiber scattering assemblies 1 that receive fiber blend from the same side.

[0246] As shown in FIG. 11, the upstream components (i.e. upstream of the fiber scattering assemblies 1) may comprise two debalers 25, the debaler belt 26 and the blend assembly 27. In such embodiments, the first debaler 25a may be used to process a single fiber material or two or more different fiber materials and the second debaler may be used to process the same or different fiber material or combination of fiber materials. In an embodiment, the first debaler 25a is a synthetic fiber debaler. In an embodiment, the second debaler 25b is a cellulose fiber debaler. In embodiments having a synthetic fiber debaler and a cellulose fiber debaler, the synthetic fiber debaler is typically placed upstream of the cellulose fiber debaler due to the light weight, high bulk fill of the synthetic fiber.

[0247] In the embodiment as shown in FIG. 11, there is a single debaler belt 26 whereby the first debaler 25a will lay a first fiber blend onto the belt, the fiber blend will be transferred downstream, and then the second debaler 25b will lay a second fiber blend atop the first fiber blend. In other embodiments, two separate debaler belts 26 may be used or the debalers may lay fiber blend onto different regions of the single debaler belt 26. The fiber blend is delivered from the debaler belt (s) 26 to the blend line assembly 27. From the blend line assembly 27, the fiber blend may be provided directly to the feed tower 3 of the one or more fiber scattering assemblies 1 or to a blend line feed tower 18 whereby the blend line feed tower 18 stores the fiber blend until it is needed and transferred to the one or more fiber scattering assemblies 1. In an embodiment, a single assembly line of the upstream components of FIG. 11 delivers fiber blend to a single fiber scattering assembly 1 (directly or via a blend line feed tower 18). In an embodiment, a single assembly line of the upstream components of FIG. 10 delivers fiber blend to two fiber scattering assemblies 1 (directly or via a blend line feed tower 18), for example two fiber scattering assemblies 1 that receive fiber blend from the same side. In an embodiment, a single assembly line of the upstream components of FIG. 10 delivers fiber blend to three of more fiber scattering assemblies 1 (directly or via a blend line feed tower 18), for example fiber scattering assemblies 1 that receive fiber blend from the same side. [0248] In exemplary operation of these upstream components, a compressed bale of fiber may be placed on a feed conveyor belt and advanced forward where it engages a vertical spike apron belt that systematically removes fiber from the bale and delivers fibers to a gravity fed fiber wire roll opener within the debaler 25. This unit provides very high separation, individualizing fibers before transferring them to the debaler belt 26 and onwards to the blend line assembly 27. Each of the debalers 25 may contain within or be interconnected to a fiber blend weigh scale. The fiber blend weigh scale of each debaler controls the feed rate from the debaler 25 onto the debaler belt 26. In an embodiment, the fiber blend weigh scale weighs the fiber blend before it is placed onto the debaler belt 26. In other embodiments, the fiber blend weigh scale weighs the fiber blend after or while it is on the debaler belt 26, and by way of a feedback mechanism adjusts the amount of subsequent fiber blend being transferred from the debaler 25 to the debaler belt 26. The fiber weigh scales may each be in communication with the PLC 4 and be controlled by the PLC 4 based on the desired formulation of the fiber blend and the status of the system as a whole.

[0249] In certain embodiments, some blending of fiber materials may be performed before the fiber materials are transferred to the blend line assembly 27. For example, two or more different fibers may be processed in a single debaler 25 and/or two or more different fibers may be placed onto the same debaler belt 26.

[0250] In certain embodiments, initial or further blending of fiber materials may be performed in the blend line assembly 27. In certain embodiments, each blend line assembly 27 may receive fiber material from one or more debalers 25 to blend and homogenize the one or more fiber materials. In certain embodiments, fiber may be blended based on density of the fiber. In certain embodiments, a light fiber, such as for example polypropylene with a density of around 0.93, may be placed on the blend line first, followed by a heavier fiber, such as for example a bast fiber with a density of around 1.35. In some embodiments, each blend line assembly 27 may receive fiber material from two or more debalers 25 to blend and homogenize the two or more fiber materials. In certain embodiments, the blend line assembly 27 may comprise a rotating wire cylinder 29 (e.g. a willow card), wherein the rotating wire cylinder 29 may comprise an agitating mechanism with for example, one or a plurality of mixing rolls, for blending the fiber. A person of skill, in light of the teachings herein, would appreciate that a willow card may represent a gentle means to blend a fiber. In certain embodiments, the blend line assembly 27 may comprise enclosed rotating wires or rotating wire cylinders for blending the fiber blend in a homogeneous mixture. In certain embodiments, the rotating wire cylinder 29 may be a willow card or other equivalent rotating wire cylinder, which may provide the blended fiber to be used to produce a multilayer composite as described herein. In certain embodiments, blending of fiber material may comprise a fiber condenser or a step of fiber condensing. A condensed fiber may result in improved weight control after blending, when compared with a fiber blend not subjected to fiber condensing. A person of skill, in light of the teachings herein, would be able to select an appropriate fiber condenser for each application.

[0251] In certain embodiments, it is contemplated that after the blending of the fiber material in the rotating wire cylinder 29, the fiber blend may be transferred to a storage vessel 31. In certain embodiments, the fiber blend may be transferred by air via an air tube 30. In certain embodiments, the air tube 30 is configured such that the air is recycled and any fiber material that does not reach the storage vessel 31 is re-introduced into the system, such us back into the rotating wire cylinder 29 or the air tube 30. In certain embodiments, the air tube 30 may be a cyclone receiver, or any equivalent known in the art and selected in light of the teachings herein. The return or recycling of air may have advantages such as, for example, maintaining a desired temperature and/or a desired humidity. The storage vessel 31 may provide a regulated feed or amount of the fiber material or fiber blend to the fiber scattering assembly 1 (directly or via a blend line feed tower 18), for example via the fiber blend delivery tube 34. In an embodiment, the fiber blend is blown through the fiber blend delivery tube by a fiber blend transfer fan 33. The storage vessel 31, blend line feed tower 18, and feed tower 3, alone or in combination depending on which of these components are included in the system, ensure on-demand delivery of the fiber blend to the two or more fiber scattering assemblies 1.

[0252] In an embodiment, prior to transfer of the fiber blend from the blend line assembly 27 to the fiber scattering assembly 1, the fiber blend is subjected to a fiber opening procedure. Thus, in an embodiment, the upstream components comprise a blend line fiber opener 32. The blend line fiber opener 32 may be positioned immediately upstream of the fiber blend transfer fan 33 so that the fibers are subjected to opening and further homogenization immediately before being sent to the fiber scattering assembly 1.

[0253] In embodiments of the system herein that include a blend line feed tower 18 between the blend line assembly 27 and the fiber scattering assembly 1, it will be appreciated that some form of transfer apparatus or device is needed to move fiber blend from the blend line feed tower 18 to the fiber scattering assembly. This may be performed by any suitable means. In an embodiment, the fiber blend is pneumatically conveyed, mechanically conveyed, or any combination thereof. In an embodiment, it is via air within a tube, and a fan may be used. In an embodiment, the air pressure may further be used to balance density feed in the cross-machine direction. [0254] In certain embodiments, the multilayer composite may be thermal processed or may undergo thermal processing by a thermal processor. As used herein “thermal processing” may refer to the application of heating or cooling to a material, such as a fiber blend, composite layer, multilayer composite, and a “thermal processor” may comprise one or more components capable of thermal processing. In certain embodiments, thermal processing may comprise any temperature between about 10°C to about 250°C or between about 20°C to about 225°C. In certain embodiments, thermal processing may comprise one or more steps of heating, cooling or pressure. In certain embodiments, thermal processing may comprise increasing the pressure on one ore more composite layers or the multilayer composite, while simultaneously applying heating or cooling. In certain embodiments, increasing pressure on the one ore more composite layers or the multilayer composite may occur independently of applying heating or cooling. In certain embodiments, the multilayer composite may be thermally processed following liquid removal.

[0255] In certain embodiments, the heating of the thermal processing may either melt a thermal set resin matrix, create a crosslinking of the thermal set resin matrix, or create a full melt of the binding resin. In certain embodiments, the pressure of the thermal processing may hold the thickness of the fiber matrix. In certain embodiments, the cooling of the thermal processing may be applied to the multilayer composite to convert resins back to solids before their release. In certain embodiments, the cooling of the thermal processing may occur when the multilayer composite is in contact with a belt, which may be required to release the multilayer composite from the belt surface. In certain embodiments, the thermal processing may occur completely or partially under clean conditions.

[0256] In certain embodiments, the thermal processor may comprise an upper belt and a lower belt. In certain embodiments, the upper belt and the lower belt may provide heating, cooling, pressure or combinations thereof. The upper belt and lower belt may comprise a plurality of regions capable of providing one or more of heating, cooling or pressure, such that the multilayer composite may be subjected to one or more regions of heating, cooling, and/or pressure. In certain embodiments, region(s) of the upper belt or the lower belt may apply heating or cooling while the opposing belt provides the opposite, i.e. the upper belt provides heating, and the lower belt provides cooling or the upper belt provides cooling, and the lower provides heating.

[0257] In certain embodiments, the upper thermal processing belt of the thermal processor may comprise two independent belts. In certain embodiments, the two independent belts of the upper belt may comprise an open space between that provides space to allow applications of secondary surface treatments including, but not limited to, powdered adhesive resins, such as for example thermoplastic polyurethane (TPU), or powder coating resins, such as those which may provide a decorative color surface. In certain embodiments, the first upper belt may comprise both heating zones and cooling zones. The use of both heating zones and cooling zones may provide a matrix surface that freely releases from a belt, such as a conveying belt.

[0258] In certain embodiments, it is contemplated that following the step of thermal processing, the composite or multilayer composite may undergo trimming to achieve a multilayer composite of a desired shape, size, area or volume. In certain embodiments, trimming may be performed with a laser. In certain embodiments, trim waste created using the step of trimming may be processed in for example, a mill, to reduce the particle size. In certain embodiments, the trim waste of a reduced particle size may be returned to an embodiment of the process or system as described herein. In certain embodiments, the trim waste may be returned to a fiber scattering assembly 1 or a recycler assembly 6.

[0259] Taking into account the description herein regarding components of the system disclosed herein, reference is made to FIG. 12 which provides a flow chart of an exemplary process 100 of the present disclosure, the process 100 including the following steps:

[0260] Step 102 of providing a fiber blend comprising one or more fiber materials to a fiber scattering assembly 1, the fiber scattering assembly 1 comprising a load cell 2 that regulates the amount of a discharged fiber blend from the fiber scattering assembly 1.

[0261] Step 104 of laying a web of the discharged fiber blend from the fiber scattering assembly

1 to form a composite layer. In an embodiment, the fibers of the composite layer are substantially non- directional in arrangement. In an embodiment, this step further comprises steps of degassing the composite layer, for example by laying the web of the discharged fiber blend onto an output conveying belt 10; contacting the web of the discharged fiber blend with a degassing belt 12; and passing the web of the discharged fiber blend between the output conveying belt 10 and the degassing belt 12 to provide the composite layer.

[0262] Step 106 of delivering the composite layer to another of the fiber scattering assemblies

1 as a previously laid composite layer 16.

[0263] Step 108 of repeating steps 102 to 106 one or more times using the previously laid composite layer(s) 16 as a substrate for layering atop thereof each subsequent composite layer to provide a plurality of layers forming the multilayer composite. In an embodiment, after any cycle of steps 102 to 106, the process may comprise steps of providing a recycled feed material to a recycler assembly 17, the recycled feed material comprising a recycled trim waste, an end of life cycle waste, or any combination thereof; and discharging a layer of the recycled feed material onto the previously laid composite layer(s) to provide a recycled layer to the multilayer composite.

[0264] Step 110 of amalgamating individual fibers in the multilayer composite to provide in-direction tensile strength, to intertwine fibers within or between composite layers, and/or to receive one or more resins.

[0265] Step 112 of infusing the one or more resins into the amalgamated individual fibers of the multilayer composite. In some embodiments, the infusing may comprise steps of transforming the one or more resins from a liquid to a foam; and infusing the foam into the amalgamated individual fibers of the multilayer composite.

[0266] Step 114 of removing liquid from the multilayer composite.

[0267] The process steps provided above may be performed in accordance with any of the embodiments described herein.

[0268] Multilayer Composites

[0269] The multilayer composites herein may be of an indefinite number of different compositions by using different fiber materials, different fiber blends, different densities, different combinations of thermal melt versus thermal set layers, different resins, etc.

[0270] Composite layers of the multilayer composites can, for example, include thermal melt fibers, or can be made with one or more different fiber types, none of which requires a thermal melt fiber. In the case where no thermal melt fiber is used in a given composite layer, a thermal set resin may be applied post formation of the multilayer composite, for example via converting liquid binders to foam and then injecting the foam from each surface side to impregnate all fibers with the thermal set resin.

[0271] Composite layers of the multilayer composites may also include or consist of recycled feed materials, thereby advantageously reusing a recyclable material within the multilayer composites herein.

[0272] In an embodiment, the present disclosure provides a non-woven multilayer composite prepared according to the process as described herein. [0273] In an embodiment, the present disclosure provides a non-woven multilayer composite prepared using the system as described herein.

[0274] In an embodiment, the present disclosure provides a non-woven multilayer composite comprising at least two composite layers, wherein the fibers of each composite layer are substantially non-directional in arrangement.

[0275] In an embodiment, the present disclosure provides a non-woven multilayer composite comprising at least two composite layers, wherein each of the at least two composite layers comprises: (i) a thermal melt fiber or polymer that is non-crimped and is between about 2 denier and about 4 denier; and (ii) one or more non-melt fibers are about 30 mm in length.

[0276] The non-woven multilayer composite of the present disclosure may comprise any number of composite layers, including without limitation two, three, four, five, six, seven or more. Each of the composite layers of the multilayer composite may individually and independently be made of the same fiber blend or different fiber blends. In an embodiment, any one or more of the fiber blends may comprise a non-melt fiber, a thermal melt fiber or polymer, a thermal set resin, or any combination thereof.

[0277] In an embodiment, one or more of the composite layers comprise or consist of one or more thermal melt fibers or polymers to provide a thermal melt composite layer in the multilayer composite. In an embodiment, one or more of the composite layers comprise or consist of one or more non-melt fibers and one or more thermal melt fibers or polymers to provide a thermal melt composite layer in the multilayer composite. In an embodiment, one or more of the composite layers comprise or consist of one or more non-melt fibers and one or more thermal set resins to provide a thermal set composite layer in the multilayer composite. In an embodiment, one or more of the composite layers comprise or consist of one or more non-melt fibers, one or more thermal melt fibers or polymers, and one or more thermal set resins to provide a thermal set and thermal melt composite layer in the multilayer composite. In an embodiment, the multilayer composites of the present disclosure may comprise any combination of composite layers as described herein. In an embodiment, the multilayer composites may further comprise one or more layers of a recycled feed material.

[0278] In an embodiment of the non-woven multilayer composite of the present disclosure, each of the layers is made of one or more non-melt fibers infused with thermal set resins to provide a thermal set composite. [0279] In an embodiment of the non-woven multilayer composite of the present disclosure, two or more of the composite layers are made from a different fiber blend, each fiber blend comprising different types of fibers and/or amounts of fibers.

[0280] In an embodiment of the non-woven multilayer composite of the present disclosure, each of the composite layers is made from a different fiber blend, each fiber blend comprising different types of fibers and/or amounts of fibers.

[0281] In an embodiment, the non-woven multilayer composite of the present disclosure is a combined thermal melt and thermal set composite, wherein at least one layer comprises thermal melt fibers or polymers and at least one layer comprises non-melt fibers with infused thermal set resins.

[0282] In an embodiment of the non-woven multilayer composite of the present disclosure, each outer layer of the multilayer composite comprises the non-melt fibers with infused thermal set resins, and two or more inner layers comprise the thermal melt fibers or polymers In an embodiment, the thermal melt fiber or polymer is polypropylene. In a further embodiment, at least one inner layer is made of or comprises a recycled feed material.

[0283] In an embodiment of the non-woven multilayer composite of the present disclosure, the one or more thermal melt fibers or polymers are non-crimped. In an embodiment, the one or more thermal melt fibers or polymers are between about 2 denier and about 3 denier. In an embodiment, the one or more thermal melt fibers or polymers are about 2 denier. In an embodiment, the one or more thermal melt fibers or polymers are between about 20 mm and about 30 mm in length. In an embodiment, the one or more thermal melt fibers or polymers are about 25 mm in length. In an embodiment, the one or more thermal melt fibers or polymers are non-crimped; are about 2 denier; and are about 25 mm in length. In an embodiment, such thermal melt fibers or polymers as described in this paragraph may be included in one or more composite layers of the multilayer composite. In an embodiment, such thermal melt fibers or polymers as described in this paragraph may be included in all composite layers of the multilayer composite.

[0284] In an embodiment of the non-woven multilayer composite of the present disclosure, the one of more non-melt fibers comprise a natural fiber, a polyester fiber, or a combination thereof. In an embodiment, the natural fiber comprises a plant-based fiber. In an embodiment, the plant-based fiber is from hemp, kenaf, jute, bamboo, or any combination thereof. In an embodiment, the plant-based fiber is a bast fiber. In an embodiment, the one or more non-melt fibers are about 30 mm in length. In an embodiment, such non-melt fibers as described in this paragraph may be included in one or more composite layers of the multilayer composite. In an embodiment, such non-melt fibers as described in this paragraph may be included in all composite layers of the multilayer composite.

[0285] In an embodiment, the non-woven multilayer composite of the present disclosure may comprise composite layers or the same of different surface density weight. In an embodiment, two or more of the composite layers are at a different surface density weight. In an embodiment, each of the composite layers are at a different surface density weight.

[0286] In an embodiment, the non-woven multilayer composite of the present disclosure may have at least one layer that comprises or consists of a recycled feed material, the recycled feed material comprising a recycled trim waste, an end of life cycle waste, or any combination thereof.

[0287] In an embodiment, the non-woven multilayer composite of the present disclosure may comprise has substantially equal strengths in both the x direction and the y direction. More particularly, in an embodiment, each composite layer in the multilayer composite is substantially equal in strength in both the x direction and the y direction.

[0288] In an embodiment, the non-woven multilayer composite of the present disclosure has one or more of the following properties:

• an increased screw retention as compared with other composite products, and in particular in comparison to other multilayer composites prepared by a process or system other than that of the present disclosure;

• provides protection from burning, in particular having a UL94 VO rating; and moreover provides improved fire protection as compared with other composite products, and in particular in comparison to other multilayer composites prepared by a process or system other than that of the present disclosure;

• has reduced composite weight as compared with other composite products, and in particular in comparison to other multilayer composites prepared by a process or system other than that of the present disclosure;

• has reduced acquisition cost as compared with other composite products, and in particular in comparison to other multilayer composites prepared by a process or system other than that of the present disclosure; is made using carbon sequestering fibers, and in particular is capable of including recyclable materials having sequestered carbon therein within an internal composite layer of the multilayer composite;

• is substantially carbon neutral or carbon negative, for example in respect of the manufacturing process and/or the ability to include recyclable materials having sequestered carbon therein within an internal composite layer of the multilayer composite; and

• is fully recyclable, for example in that the multilayer composite is produced entirely of recyclable material, and more particularly of material that can be re-used as the recycled feed material in later generations of products.

[0289] Accordingly, as described herein are multilayer composites, and processes and systems for the preparation thereof, which comprise two or more composite layers of fiber blend and/or recycled feed material. The multilayer composites may offer a number of advantages over existing technologies and products, including without limitation those described herein.

[0290] Examples

[0291] The following examples are presented to illustrate and demonstrate aspects of the disclosure and should not be construed as limiting.

[0292] The present disclosure provides a new and advantageous technology to manufacture multilayer composites, and in particular multilayer composites comprising two or more fibers for the purpose of producing molded articles of products that would directly replace wood-based fiber products and traditional plastic shaped products that are used across a broad spectrum of markets including but not limited to automotive, building construction, aerospace, furniture, and a host of other common and non-common products.

[0293] Traditional non-woven composites are not individually layered. In contrast, by way of the systems and processes herein, each composite layer may be individually weight controlled separately from the other layers. Product improvements from the systems and processes herein also include the development of a new standard for non-woven multilayer composites from traditional +/- 10% deviation in surface area density, to an improved +/- 5% deviation in surface area density, that reduces product weight without loss of performance values. Moreover, as disclosed herein, the processes and systems herein allow for the recycling of materials, thereby maintaining the carbon content sequestered within the products and not deposited into landfills.

[0294] Example 1 - Tensile Strength Testing

[0295] A multilayer composite of the present disclosure was prepared on a test line. The test line comprised a single fiber scattering assembly of the present disclosure. The fiber scattering assembly was used to produce each composite layer. Composite layers were then laid upon each other in opposite machine direction to provide a multilayer composite having five layers of composite material.

[0296] Two types of fibers were used to prepare each composite layer. In this example, the first fiber was a 30 mm long hemp bast fiber. The second fiber was a synthetic fiber (polypropylene) that was not crimped, was cut to a 25 mm length, and was about 2 denier. The ability to use fibers with these characteristics in the processes of the present disclosure facilitates an increased fiber count and improves product strength and performance consistency. For example, the use of the bast fiber provides an about 2.8 times increase in fiber count over traditional methodologies and the use of non-crimped synthetic fiber provides an about 5 times increase in fiber count over traditional technologies. In addition, the processes and systems disclosed herein are capable of achieving high performance values at significantly reduced weight.

[0297] By reference to traditional methodologies, it is intended to refer to typical procedures for manufacturing non-woven composites whereby cellulose fiber (e.g. hemp bast fiber) having a cut length of 75-100 mm are bundled (25 or more individual fibers) and attached to each other by lignin. In traditional methodologies, synthetic fibers are crimped at 10 crimps per inch to provide irregular surface direction to aid in transfer and blending between the different fiber types (e.g. synthetic and nonsynthetic). In traditional methodologies, crimp fibers facilitate manufacturing of non-woven composites on carding systems. Crimp fibers also trend to stick together in quantities similar to bast fiber, and due to issues with opening are restricted to deniers of no less than 4 (and normally 6) or pilling will occur.

[0298] In preparing the multilayer composite of the present disclosure, the synthetic fibers were fed into a synthetic fiber debaler. A compressed bale of fiber was placed on a feed conveyer belt and advanced forward where it engages a vertical spike apron belt that systematically removes fiber from the bale and delivers fibers to a gravity fed fiber wire roll opener. This unit provides high separation, individualizing fibers before sending them on for further processing. Thus, the synthetic fibers were pre -opened upon exit from the synthetic fiber debaler. This separates fibers even though they are not crimped. [0299] In preparing the multilayer composite of the present disclosure, the hemp bast fibers were fed into a cellulose fiber debaler and fiber opening system, again providing high separation and individualizing fibers before sending them on for further processing.

[0300] Each of the fiber debalers includes a fiber weigh scale. The weigh scales were used to control the fiber feed rate in a regulated manner into the blend line assembly. Synthetic fibers were laid first due to their light weight, high bulk fill. The hemp bast fibers were then laid atop and both fibers were fed into the blend line assembly on a belt. For the multilayer composites of this example, a fiber blend having about a 50/50 mix of synthetic fiber and cellulose fiber was used.

[0301] In traditional methodologies, conventionally prepared fibers are processed through a fine opener that provides some ability to deconstruct fiber bundles and provide initial blending of cellulose and synthetic fibers for downstream processing. The blended fibers are then typically fed to a weight pan to control feed rate, which establishes the blend of each fiber type in the composite layer. At the end of the blend line, combined fibers are further blended together using either a willow card or some other form of pin rolls.

[0302] The processing of the multilayer composites of the present disclosure is similar, but stages product differently. Pre -opened synthetic fibers were weight fed onto a blend belt and then pre -opened cellulose fibers were weight fed and deposited on top of the synthetic fibers, and the combined layer is only then blended together using a rotating wire cylinder (e.g. willow card).

[0303] After blending in the rotating wire cylinder, the blended fiber was delivered to a storage vessel. Having a storage vessel ensures on-demand delivery of the blended fiber to the fiber scattering assembly. Immediately prior to transfer (by air) to the fiber scattering assembly, the blended fiber was passed through a final fiber opener to complete the homogeneous blending of the fibers prior to layering. From the final fiber opener, a transfer fan was used to blow the fibers to a primary feed tower associated with the fiber scattering assembly. From the primary feed tower, blended fiber was transferred on-demand into a layering line feed tower of the fiber scattering assembly.

[0304] Uniquely, by way of the processes of the present disclosure, the blended fiber is fed from the feed tower to a fiber scattering assembly as described. In the context of this example, the blended fiber was fed to the same fiber scattering assembly to produce each composite layer since a sequential series of fiber scattering assemblies was not yet in operation. Each composite layer was then placed on top of the other in opposite machine direction and thermally bonded together to provide a multilayer composite having five layers of composite material. [0305] The multilayer composites were manufactured as described above by an independent third party. Multilayer composites having a targeted thickness of 1.2 mm, 2.0 mm and 2.5 mm were prepared. Overall, 600 multilayer composites were prepared in 10 lots. Half of the multilayer composites were then tested for tensile strength by the same third party, and the other half were tested by a certified testing facility chosen by the third party. Testing was compared to commercial products of similar formulation and weight from two other well-known non-woven composite suppliers. The results (averaged) are set forth in Tables 1-3 below. The target density (1200 gsm) was chosen by the independent third party. The abbreviations are as follows: NAH = INCA Renewtech multilayer composite of present disclosure; NAHM = INCA Renewtech multilayer composite of present disclosure with 2% maleic anhydride acid added to polypropylene; Compl = comparison commercial product of a first company; Comp2 = comparison commercial product of a second company; CC = cross-machine direction; and FA = in-machine direction.

Table 1: Tensile Properties for 1.2 mm products

[0306] As shown in the table above, the comparison commercial products from Compl were about 57% (CC direction) and about 85% (FA direction) as effective as the multilayer composites of the present disclosure. The comparison commercial products from Comp2 were about 51% (CC direction) and about 70% (FA direction) as effective as the multilayer composites of the present disclosure. Thus, all of the comparison commercial products underperformed as compared to the multilayer composites of the present disclosure. The multilayer composites of the present disclosure performed between about 15% and about 49% better than the comparison commercial products. Table 2: Tensile Properties for 2.0 mm products

[0307] As shown in the table above, the comparison commercial products from Compl were about 64% (CC direction) and about 69% (FA direction) as effective as the multilayer composites of the present disclosure. The comparison commercial products from Comp2 were about 64% (CC direction) and about 65% (FA direction) as effective as the multilayer composites of the present disclosure. Thus, all of the comparison commercial products underperformed as compared to the multilayer composites of the present disclosure. The multilayer composites of the present disclosure performed between about 31% and about 36% better than the comparison commercial products.

Table 3: Tensile Properties for 2.5 mm products [0308] As shown in the table above, the comparison commercial products from Compl were about 105% (CC direction) and about 73% (FA direction) as effective as the multilayer composites of the present disclosure. The comparison commercial products from Comp2 were about 57% (CC and FA directions) as effective as the multilayer composites of the present disclosure. Thus, most of the comparison commercial products underperformed as compared to the multilayer composites of the present disclosure. Aside from one competitor commercial product that performed about 5% better, the multilayer composites of the present disclosure performed between about 27% and about 43% better than the comparison commercial products. [0309] It is relevant to note that these results for the multilayer composites of the present disclosure were obtained using multilayer composites that in which each composite layer was prepared from a single fiber scattering assembly and then each individual layer was hand laid atop the other with gaps in time between the layers being prepared. It is anticipated that when the multilayer composites are preparing by the processing line and systems disclosed herein, the improvements over comparison commercial products and characteristics of the multilayer composites will be significantly better.

[0310] Example 2 - Bend Property Testing

[0311] Multilayer composites of the present disclosure were prepared on a test line as described in Example 1. As stated in Example 1, the multilayer composites were manufactured by an independent third party. Multilayer composites having a targeted thickness of 1.2 mm, 2.0 mm and 2.5 mm were prepared. Overall, 600 multilayer composites were prepared in 10 lots.

[0312] Half of the multilayer composites were then tested for bend properties by the same third party, and the other half were tested by a certified testing facility chosen by the third party. Testing was compared to commercial products of similar formulation and weight from two other well-known non-woven composite suppliers. The results (averaged) are set forth in Tables 4-6 below. The target density (1200 gsm) was chosen by the independent third party. The abbreviations again are as follows: NAH = INCA Renewtech multilayer composite of present disclosure; NAHM = INCA Renewtech multilayer composite of present disclosure with 2% maleic anhydride acid added to polypropylene; Comp 1 = comparison commercial product of a first company; Comp2 = comparison commercial product of a second company; CC = cross-machine direction; and FA = in-machine direction.

Table 4: Bend Properties for 1.2 mm products

Table 5: Bend Properties for 2.0 mm products

Table 6: Bend Properties for 2.5 mm products

[0313] As shown in Table 4 above (1.2 mm), the comparison commercial products from

Compl were about 57% (CC direction) and about 85% (FA direction) as effective in handling bend stress as the multilayer composites of the present disclosure. The comparison commercial products from Comp2 were about 54% (CC direction) and about 81% (FA direction) as effective in handling bend stress as the multilayer composites of the present disclosure. Thus, all of the comparison commercial products underperformed as compared to the multilayer composites of the present disclosure. The multilayer composites of the present disclosure performed between about 15% and about 46% better than the comparison commercial products in handling bend stress.

[0314] As shown in Table 5 above (2.0 mm), the comparison commercial products from

Compl were about 99% (CC direction) and about 54% (FA direction) as effective in handling bend stress as the multilayer composites of the present disclosure. The comparison commercial products from Comp2 were about 91% (CC direction) and about 53% (FA direction) as effective in handling bend stress as the multilayer composites of the present disclosure. Thus, all of the comparison commercial products underperformed as compared to the multilayer composites of the present disclosure. The multilayer composites of the present disclosure performed between about 1% and about 47% better than the comparison commercial products in handling bend stress.

[0315] As shown in Table 6 above (2.5 mm), the comparison commercial products from

Compl were about 89% (CC direction) and about 97% (FA direction) as effective in handling bend stress as the multilayer composites of the present disclosure. The comparison commercial products from Comp2 were about 59% (CC direction) and about 66% (FA direction) as effective in handling bend stress as the multilayer composites of the present disclosure. Thus, all of the comparison commercial products underperformed as compared to the multilayer composites of the present disclosure. The multilayer composites of the present disclosure performed between about 3% and about 41% better than the comparison commercial products in handling bend stress.

[0316] The multilayer composites of the present disclosure also performed better in respect to specific modulus, with all demonstrating better results with the exception of the 2.0 mm NAH - CC compared to the Compl - CC product.

[0317] Therefore, the present disclosure is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual embodiments are discussed, the disclosure covers all combinations of all those embodiments. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.

[0318] Many obvious variations of the embodiments set out herein will suggest themselves to those skilled in the art in light of the present disclosure. Such obvious variations are within the full intended scope of the appended claims.