The present invention is directed to plant fiber-reinforced biocomposite thermoplastic and/or resin compositions and a method for reinforcing thermoplastic resins. The present invention provides a use for the cellulose portion of a plant material, which is the portion left over after processing the selected plant materials to separate the cellulose in a mechanical process that does not damage the internal molecular structure of the cellulose fraction, enabling the cellulose fraction to chemically bond with the thermoplastic resin to enhance the reinforcement of the resin or thermoplastic biocomposite composition.

The present invention is directed to plant fiber-reinforced biocomposite thermoplastic and/or resin compositions and a method for reinforcing thermoplastic resins. The present invention provides a use for the cellulose portion of a plant material, which is the portion left over after processing the selected plant materials to separate the cellulose in a mechanical process that does not damage the internal molecular structure of the cellulose fraction, enabling the cellulose fraction to chemically bond with the thermoplastic resin to enhance the reinforcement of the resin or thermoplastic biocomposite composition.

A method of forming carded fibers of different materials. A feed system has a plurality of separate laterally spaced chambers containing fibers of different materials. The different fibers are fed in separate laterally spaced paths into a carding apparatus having a plurality of rollers and cylinders each having laterally spaced sections in alignment with the laterally spaced paths to receive and maintain the different fibers in the laterally spaced paths thereon as they move through the carding apparatus. The different fibers are combined into a multi-fiber roving or web after they exit the carding apparatus. Depending on the composition of the different fibers, they may be combined by conveying them through a humidifying and heated chamber or chambers.

A method of forming carded fibers of different materials. A feed system has a plurality of separate laterally spaced chambers containing fibers of different materials. The different fibers are fed in separate laterally spaced paths into a carding apparatus having a plurality of rollers and cylinders each having laterally spaced sections in alignment with the laterally spaced paths to receive and maintain the different fibers in the laterally spaced paths thereon as they move through the carding apparatus. The different fibers are combined into a multi-fiber roving or web after they exit the carding apparatus. Depending on the composition of the different fibers, they may be combined by conveying them through a humidifying and heated chamber or chambers.

Methods and systems are provided for a process to generate a nonwoven textile. In one example, the nonwoven textile may have layered, zonal properties resulting from entangling of two or more types of staple fibers through a merging region between the layers of staple fibers while maintaining distinct zones, each zone comprising a type of staple fiber. Furthermore, the process may include embedding a filament layer into the nonwoven textile via a continuous assembly line.