A method of forming a fibrous structure including: providing a first textured substrate that has a first side with first discrete regions and a first continuous region extending between the first discrete regions, and a second side comprising a plurality of first discrete portions corresponding to the first discrete regions and a first continuous portion corresponding to the first continuous region; passing the first textured substrate across a nozzle of a slot coat header, wherein a heated polymer is dispensed from the nozzle; depositing the heated polymer onto one of the first or the second side of the first textured substrate to form a plurality of first polymer particles, wherein the heated polymer is substantially deposited on an area of the first textured substrate that contacts the nozzle such that at least a section of each of the first polymer particles defines a raised edge; and joining the first textured substrate to a second substrate to form the fibrous structure.

A method of forming a fibrous structure including: providing a first textured substrate that has a first side with first discrete regions and a first continuous region extending between the first discrete regions, and a second side comprising a plurality of first discrete portions corresponding to the first discrete regions and a first continuous portion corresponding to the first continuous region; passing the first textured substrate across a nozzle of a slot coat header, wherein a heated polymer is dispensed from the nozzle; depositing the heated polymer onto one of the first or the second side of the first textured substrate to form a plurality of first polymer particles, wherein the heated polymer is substantially deposited on an area of the first textured substrate that contacts the nozzle such that at least a section of each of the first polymer particles defines a raised edge; and joining the first textured substrate to a second substrate to form the fibrous structure.

A support (100) for handling pre-formed woven fabric layers to be used for conical shell composite components or segments is described. The support comprises a shaped portion (120) having a plurality of peaks (170) and a plurality of troughs (180) extending between first and second longitudinal edges (130, 140). Each peak has a varying amplitude along its extent and is configured to maintain warp and weft fibres of the pre-formed woven fabric layers perpendicular to one another. A clamping member may be used to retain a stack of pre-formed woven fabric layers in place on the support. The support may also be used for forming non-woven fibre layers and stacks formed from such non-woven fibre layers, and, for the subsequent handling thereof.

A hollow cylindrical carbon fiber construction, including a carbon fiber nonwoven, which is continuous between the inner lateral surface and the outer lateral surface of the carbon fiber construction all around. The hollow cylindrical carbon fiber construction can be obtained by a method in which a hollow cylindrical starting fiber construction, which includes a nonwoven that is continuous between the inner lateral surface and the outer lateral surface of the starting fiber construction all around, is subjected to a pyrolysis process.

A hollow cylindrical carbon fiber construction, including a carbon fiber nonwoven, which is continuous between the inner lateral surface and the outer lateral surface of the carbon fiber construction all around. The hollow cylindrical carbon fiber construction can be obtained by a method in which a hollow cylindrical starting fiber construction, which includes a nonwoven that is continuous between the inner lateral surface and the outer lateral surface of the starting fiber construction all around, is subjected to a pyrolysis process.

Insulation element for thermal and/or acoustic insulation of a flat roof, comprising a first layer made of mineral wool and a second layer made of at least one fabric, whereby the second layer is fixed to a major surface of the first layer by an adhesive, whereby the first layer is made of at least one lamella having a fiber orientation predominantly perpendicular to major surfaces of the second layer, whereby the first layer contains a cured binder whereby the adhesive is arranged partly in an area between fibers close to the major surface of the first layer directed to the second layer and in an area close to the major surface of the second layer directed to the first layer so that the adhesive connects the first layer and the second layer in such a way that forces directed perpendicular to the second layer can be compensated by the tensile strength of the second layer in combination with the adhesive and/or the deflection of the fibers of the first layer causing a maximum deformation of ≤5% of the thickness of the first and second layer.

Method for producing a fibrous mat, which can be installed in a component of a vehicle provided with an internal combustion engine for acoustically and thermally insulating the component. The method comprises the steps of: providing a fibrous core consisting of at least one fibrous bundle that extends along a direction that is approximately parallel to a longitudinal axis; wrapping the outer surface of the fibrous core by means of a fibrous bundle that extends along a direction that is approximately transverse to the bundle of the fibrous core, thus providing at least one outer tubular fibrous containment sleeve that extends, in turn, along the longitudinal axis and covers the outer surface of the fibrous core to trap the fibrous core therein.

Method for producing a fibrous mat, which can be installed in a component of a vehicle provided with an internal combustion engine for acoustically and thermally insulating the component. The method comprises the steps of: providing a fibrous core consisting of at least one fibrous bundle that extends along a direction that is approximately parallel to a longitudinal axis; wrapping the outer surface of the fibrous core by means of a fibrous bundle that extends along a direction that is approximately transverse to the bundle of the fibrous core, thus providing at least one outer tubular fibrous containment sleeve that extends, in turn, along the longitudinal axis and covers the outer surface of the fibrous core to trap the fibrous core therein.

A method for making a high topography nonwoven substrate includes generating a foam including water and synthetic binder fibers; depositing the foam on a planar surface; disposing a template form on the foam opposite the planar surface to create a foam/form assembly; heating the foam/form assembly to dry the foam and bind the synthetic binder fibers; and removing the template from the substrate after heating the foam/form assembly, wherein the substrate includes a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.

A method for making a high topography nonwoven substrate includes generating a foam including water and synthetic binder fibers; depositing the foam on a planar surface; disposing a template form on the foam opposite the planar surface to create a foam/form assembly; heating the foam/form assembly to dry the foam and bind the synthetic binder fibers; and removing the template from the substrate after heating the foam/form assembly, wherein the substrate includes a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.