A liquid binder composition for binding fibrous materials in the fabrication of resin-infusible preform is disclosed. The binder composition is an aqueous dispersion containing (a) one or more multifunctional epoxy resins, (b) at least one thermoplastic polymer, (c) one or more surfactants selected from anionic surfactants, nonionic surfactants, and combinations thereof, (d) water, and is essentially free of organic solvents. Also disclosed is an emulsification process for producing the liquid binder composition.

A composite panel with a thermosetting cellular matrix, a method for manufacturing said panel, and a structure for covering a wall that is formed from an assembly of such panels. The structure provides the wall with heat insulation against cryogenic fluids and/or protection against fire or flames and/or sealing against the fluids. A panel having a thermosetting cellular matrix, includes at least one substrate that includes short, non-woven basalt fibers and is impregnated by the matrix. The panel is such that the at least one substrate includes a plurality of non-woven layers stacked to a stacking thickness. The non-woven layers each include the short basalt fibers and are needled through the thickness without using thermoplastic fibers.

The present invention relates to a method for manufacturing a highly heat-resistant sound absorbing and insulating material, more specifically to a method including a beating and mixing step, a web forming step, a web stacking step, a needle punching step, a binder impregnating step and a solvent recovering step. The highly heat-resistant sound absorbing and insulating material manufactured by the method according to the present invention may be installed on a location closest to the noise source of an engine or an exhaust system to reduce radiated noise from the engine or the exhaust system, thereby improving quietness inside a vehicle, and may be applied to a location adjacent to a metal part which is at a temperature of 200 C. or greater to exert heat-insulating function, thereby protecting nearby plastic and rubber parts.

The present invention relates to a method for manufacturing a highly heat-resistant sound absorbing and insulating material, more specifically to a method including a beating and mixing step, a web forming step, a web stacking step, a needle punching step, a binder impregnating step and a solvent recovering step. The highly heat-resistant sound absorbing and insulating material manufactured by the method according to the present invention may be installed on a location closest to the noise source of an engine or an exhaust system to reduce radiated noise from the engine or the exhaust system, thereby improving quietness inside a vehicle, and may be applied to a location adjacent to a metal part which is at a temperature of 200 C. or greater to exert heat-insulating function, thereby protecting nearby plastic and rubber parts.

A liquid binder composition for binding fibrous materials in the fabrication of resin-infusible preform is disclosed. The binder composition is an aqueous dispersion containing (a) one or more multifunctional epoxy resins, (b) at least one thermoplastic polymer, (c) one or more surfactants selected from anionic surfactants, nonionic surfactants, and combinations thereof, (d) water, and is essentially free of organic solvents. Also disclosed is an emulsification process for producing the liquid binder composition.

A liquid binder composition for binding fibrous materials in the fabrication of resin-infusible preform is disclosed. The binder composition is an aqueous dispersion containing (a) one or more multifunctional epoxy resins, (b) at least one thermoplastic polymer, (c) one or more surfactants selected from anionic surfactants, nonionic surfactants, and combinations thereof, (d) water, and is essentially free of organic solvents. Also disclosed is an emulsification process for producing the liquid binder composition.

According to one embodiment, a method of forming a facer includes forming a first layer of nonwoven glass fibers and positioning a second layer of reinforcement fibers atop the first layer of nonwoven glass fibers. The method also includes coating the first layer of nonwoven glass fibers and/or the second layer of reinforcement fibers with a binder composition and pressing the first layer of nonwoven glass fibers and the second layer of reinforcement fibers together between a pair of rollers. The binder composition is then dried to couple the first layer of nonwoven glass fibers and the second layer of reinforcement fibers to form the facer. The first layer of nonwoven glass fibers and/or the second layer of reinforcement fibers are free of a material coating prior to coating of the binder composition.

According to one embodiment, a method of forming a facer includes forming a first layer of nonwoven glass fibers and positioning a second layer of reinforcement fibers atop the first layer of nonwoven glass fibers. The method also includes coating the first layer of nonwoven glass fibers and/or the second layer of reinforcement fibers with a binder composition and pressing the first layer of nonwoven glass fibers and the second layer of reinforcement fibers together between a pair of rollers. The binder composition is then dried to couple the first layer of nonwoven glass fibers and the second layer of reinforcement fibers to form the facer. The first layer of nonwoven glass fibers and/or the second layer of reinforcement fibers are free of a material coating prior to coating of the binder composition.

Fibrous structures, for example pre-moistened fibrous structures, having a novel contact surface (micro protrusion surface) and methods for using the fibrous structures and making the fibrous structures are provided.

Fibrous structures, for example pre-moistened fibrous structures, having a novel contact surface (micro protrusion surface) and methods for using the fibrous structures and making the fibrous structures are provided.