A hydrophobic needle-felted insulation blanket having a textile-grade needle felted fiberglass blanket having a density in the range of 4 to 15 lb/ft3 (65 to 250 g/L) contains a uniform hydrophobic fluoropolymer disposed homogeneously throughout the textile grade needle felted fiberglass blanket without creating a higher density of hydrophobic fluoropolymer near edges of the textile-grade needle felted fiberglass blanket. The fluoropolymer has a melting point over 5500 Fahrenheit and decomposed residual hydrophilic compounds uniformly disposed through the textile grade needle felted fiberglass blanket. The finished hydrophobic needle-felted insulation blanket is (i) temperature stable up to 5500 Fahrenheit, (ii) moldable, (iii) silica dust free, and thereafter retains a selected shape and the finished blanket will not decompose, disintegrate, or lose structural integrity when submerged in water. The finished blanket comprises by weight: 60%-95% glass fiber 2%-30% hydrophobic flouropolymer, and non-decomposed hydrophilic opacifier.

Fibrous insulation products have an aqueous binder composition that includes a carbohydrate and a crosslinking agent. In exemplary embodiments, the carbohydrate-based binder composition may also include a catalyst, a coupling agent, a process aid, a crosslinking density enhancer, an extender, a moisture resistant agent, a deducting oil, a colorant, a corrosion inhibitor, a surfactant, a pH adjuster, and combinations thereof. The carbohydrate may be natural in origin and derived from renewable resources. Additionally, the carbohydrate polymer may have a dextrose equivalent (DE) number from 2 to 20. In at least one exemplary embodiment, the carbohydrate is a water-soluble polysaccharide such as dextrin or maltodextrin and the crosslinking agent is citric acid. Advantageously, the carbohydrates have a low viscosity and cure at moderate temperatures. The environmentally friendly, formaldehyde-free binder may be used in the formation of insulation materials and non-woven chopped strand mats. A method of making fibrous insulation products is also provided.

A method for providing a foamed, opacifying element includes providing a foamable aqueous composition, aerating it to a foam density of 0.1-0.5 g/cm.sup.3, applying the foamed aqueous composition to a porous substrate, drying, and densifying the dried layer. Such foamable aqueous compositions have 0.05-15 weight % of porous particles; at least 20 weight % of a binder; at least 0.0001 weight % of additives (including a surfactant); water; and at least 0.001 weight % of an opacifying colorant. Each porous particle includes a continuous polymeric phase and discrete pores; a mode particle size of 2-50 m; and a porosity of 20-70 volume %. The continuous polymeric phase T.sub.g is >80 C. and has a polymer viscosity of 80-500 centipoises at an ethyl acetate shear rate of 100 sec.sup.1 at a concentration of 20 weight % at 25 C.

A method for providing a foamed, opacifying element includes providing a foamable aqueous compositions, aerating it to a foam density of 0.1-0.5 g/cm.sup.3, applying the foamed aqueous composition to a porous substrate, drying, and densifying the dried layer Such foamable aqueous compositions have 0.05-15 weight % of porous particles; at least 20 weight % of a binder; at least 0.0001 weight % of additives (including a surfactant); water; and at least 0.001 weight % of an opacifying colorant. Each porous particle includes a continuous polymeric phase and discrete pores; a mode particle size of 2-50 m; and a porosity of 20-70 volume %. The continuous polymeric phase T.sub.g is>80 C. and has a polymer viscosity of 80-500 centipoises at an ethyl acetate shear rate of 100 sec.sup.1 at a concentration of 20 weight % at 25 C.

Hydrophobic thermal insulation fiberglass flexible blanket using a textile grade fiberglass is produced by impregnating a hydrophobic polymer (e.g. a fluoropolymer) dispersion into a fiberglass blanket/mat, such as a needle felted fiberglass (FG) blanket/mat. The preferred FG needle felt blanket is a mechanically, rather than organically, bound glass fiber insulating blanket. The hydrophobic polymer dispersion forms a hydrophobic coating on the surface of the fiberglass filaments. Integral hydrophobicity is achieved and maintained without the need to add commonly-used hydrophobic inorganic particles, such as treated silica aerogels or fumed silica. Optionally, to enhance overall hydrophobicity and to inhibit fibrous surface lofting, a super-hydrophobic coating of fluoropolymer and inorganic particles such as silica particles may be dispersed onto one or more surfaces of the blanket. The resulting blanket thermally insulates better than mineral wool; it is equal in insulating properties to (or is slightly better than) untreated FG mat; and it slightly less insulating than aerogel-based blanket materials. It is relatively inexpensive to manufacture, it is flexible, it is durable, it can optionally be made moldable, it eliminates dust, and it remains hydrophobic after long-term heating to 600 F. (315 C.), or after short-term excursions to temperatures as high as 700 F. (370 C.).

An aqueous binder composition is disclosed that includes 5.0% by weight to 50.0% by weight of a monomeric polyol having at least four hydroxyl groups, based on the total solids content of the aqueous binder composition; and at least 50.0% by weight of a cross-linking agent comprising a polymeric polycarboxylic acid having at least two carboxylic acid groups, based on the total solids content of the aqueous binder composition. The aqueous binder composition includes a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.15/1.0 and 2.23/1 and has a pH of 2.2 to 4.0 and a viscosity at 40% solids and 25 C. of 10 cP to 60 cP.

A fabric having resilient prominences on at least one surface is described for improved thermal protection, drag reduction and quick drying. Resilient prominences are bulges that extend outward from a fabric surface and trap some volume of air or other material therein. For example, a resilient prominence may be dome shaped and extend outward from the fabric plane. A resilient prominence is resilient in shape, whereby the resilient prominence may be compressed and then popped back into substantially the original shape. Reflective and/or absorptive materials may be configured on the surface of the fabric to provide camouflage from IR cameras. Reflective material may be configured on the fabric to reflect heat back to the wearer of a garment made with the fabric described.

Lightweight, flexible protective fabrics for protecting a person, animal or other object from hot burning materials, hot high heat capacity and/or hot corrosive materials, such as hot molten metal, hot oily liquids (e.g., heating oil), hot gels, hot solids, hot sparks, and hot acids. The lightweight protective fabrics can be used to protect a person, animal or other object from hot molten metals, such as liquid metal zinc heated to a temperature of about 950 F. (510 C.) or greater, hot molten aluminum heated to a temperature of about 1150 F. (620 C.) or greater, burning phosphorus at temperature of about 1550 F. (843 C.) or greater, hot solid iron having a temperature of about 500 F. (260 C.) or greater, hot heating oil having a temperature of about 500 F. (260 C.) or greater, and hot hydrochloric acid having a temperature of about 300 F. (150 C.) or greater.

Apparatus are provided for a device with improved heat resistance. The device includes a body and an encasing layer disposed substantially entirely around the body. The encasing layer includes a fabric layer and a coating. The fabric layer has a first end and a second end coupled together about the perimeter of the body to enclose the body, and the fabric layer includes an exterior surface. The coating is disposed on the exterior surface of the fabric layer, and the coating forms a barrier for the fabric layer.

An insulative moisture vapor transmission membrane with reflective barrier is provided. A method of manufacturing the membrane includes providing metallic powder and incorporating it into a liquefied polyurethane. The membrane may be incorporated into wearable garments either directly, or in a laminate form.