COMPOSITE MATERIALS AND METHODS FOR MAKING THE SAME

1 . A composite material comprising:

from 1% to 99% by weight of a fibrous material comprising cellulosic fibers, by weight of the composite material; and

from 1% to 50% by weight of a binding material, by weight of the composite material,

wherein the composite material has a density of 0.8 g/cm 3 to 1.5 g/cm 3 .

2 . The composite material of claim 1 , wherein the binding material comprises a bicomponent fiber, a monocomponent fiber, or a combination thereof.

3 . The composite material of claim 1 , wherein the bicomponent fiber has (i) a core comprising polyethylene, polyethylene terephthalate, polyester, polypropylene, polyvinyl chloride, polystyrene, polymethacrylate, polyethylene naphthalate, polyvinyl alcohol, polyurethane, polyacrylonitrile, polylactic acid (PLA), polyhydroxyalkanoates (PHA) or combinations thereof, and (ii) a sheath comprising polyethylene, polyethylene terephthalate, polyester, polypropylene, polyvinyl chloride, polystyrene, polymethacrylate, polyethylene naphthalate, polyvinyl alcohol, polyurethane, polyacrylonitrile, polylactic acid (PLA), polyhydroxyalkanoates (PHA) or combinations thereof, provided that the polymer in the sheath has a lower melting temperature than the polymer in the core.

4 . The composite material of claim 1 , wherein the density of the composite material is 1.1 g/cm 3 to 1.4 g/cm 3 .

5 . The composite material of claim 1 , wherein the composite material has a tensile strength of 15 MPa or greater, a flexural strength of 15 MPa or greater, or both.

6 . The composite material of claim 1 , wherein the composite material has a tensile modulus of 0.75 GPa or greater, a flexural modulus of 0.75 GPa or greater, or both.

7 . The composite material of claim 1 , wherein the composite material has a tensile strength of 50 MPa or greater, a flexural strength of 50 MPa or greater, or both.

8 . A method comprising:

heating a mat to a temperature; and

compressing the mat at a first pressure of 800 psi to 6000 psi into one of a two-dimensional panel or a three-dimensional shape;

wherein the mat comprises:

from 1% to 99% by weight of a fibrous material comprising cellulosic fibers; and

from 1% to 50% by weight of a binding material,

wherein the temperature is above the melting point of the binding material, and

wherein the mat is incorporated into a composite material.

9 . The method of claim 8 , further comprising cooling the two-dimensional panel or three-dimensional shape to a temperature below the melting point of the binding material after the step of compressing the mat.

10 . The method of claim 8 , wherein the temperature is from 40° C. to 200° C.

11 . The method of claim 8 , further comprising forming the two-dimensional panel into a contoured two-dimensional panel or three-dimensional shape at a second pressure of 15 psi to 500 psi.

12 . The method of claim 8 , wherein the first pressure is from 850 psi to 5000 psi.

13 . The method of claim 11 , wherein the heating and compressing are simultaneous.

14 . The method of claim 11 , further comprising cooling the contoured two-dimensional panel or three-dimensional shape to a temperature below the melting point of the binding material after the step of forming the two-dimensional panel.

15 . The method of claim 8 , wherein the first and/or second pressure occurs at a temperature is above the melting point of the binding material.

16 . A composite material produced by the method of claim 8 , wherein the composite material has a density of 1.1 g/cm 3 to 1.4 g/cm 3 .

17 . The method of claim 8 , wherein the binding material comprises a bicomponent fiber, a monocomponent fiber, or a combination thereof.

18 . The method of claim 17 , wherein the bicomponent fiber has (i) a core comprising polyethylene, polyethylene terephthalate, polyester, polypropylene, polyvinyl chloride, polystyrene, polymethacrylate, polyethylene naphthalate, polyvinyl alcohol, polyurethane, polyacrylonitrile, polylactic acid (PLA), polyhydroxyalkanoates (PHA) or combinations thereof, and (ii) a sheath comprising polyethylene, polyethylene terephthalate, polyester, polypropylene, polyvinyl chloride, polystyrene, polymethacrylate, polyethylene naphthalate, polyvinyl alcohol, polyurethane, polyacrylonitrile, polylactic acid (PLA), polyhydroxyalkanoates (PHA) or combinations thereof, provided that the polymer in the sheath has a lower melting temperature than the polymer in the core.

19 . The method of claim 8 , wherein the composite material has a tensile modulus of 0.75 GPa or greater, a flexural modulus of 0.75 GPa or greater, or both.

20 . The method of claim 8 , wherein the composite material has a tensile strength of 50 MPa or greater, a flexural strength of 50 MPa or greater, or both.

21 . The method of claim 8 , wherein the mat is a wetlaid mat.

22 . The method of claim 8 , wherein the mat is an airlaid mat.

23 . The method of claim 11 , wherein the density of the contoured two-dimensional panel or the three-dimensional shape is substantially the same as that of a two-dimensional panel.