A form for a thin reinforced composite material includes a plurality of separate linear fiber strips, each having a rectangular cross section composed of reinforcement fibers. The linear fiber strips laid out in a two-dimensional base layer defining a shape of the form. A first successive layer formed with the plurality of separate linear fiber strips contacting the base layer, the linear fiber strips laid out in the first successive layer interspersed from the separate linear fiber strips in the two-dimensional base layer. A method of forming the form includes arranging the plurality of separate linear fiber strips on a substrate and tacking the plurality of separate linear fiber strips to the substrate with a plurality of stitches. A method of forming a unitary reinforced composite component from the form is further provided. The resulting component having high strength and light weight and being efficient to manufacture.

The present invention is directed to an acoustical baffle that has use in vehicle interiors, such as an interior headliner. In particular, the baffle can provide improved acoustics while maintaining a desired airflow resistance and can be configured to provide for different sound attenuation characteristics at selected locations of the baffle construction.

The present invention is directed to an acoustical baffle that has use in vehicle interiors, such as an interior headliner. In particular, the baffle can provide improved acoustics while maintaining a desired airflow resistance and can be configured to provide for different sound attenuation characteristics at selected locations of the baffle construction.

A composite nonwoven mat and a method of making a composite nonwoven mat are provided. The composite nonwoven mat includes a nonwoven base layer having a first surface and a second surface, and a coating layer formed on, penetrating into, and adhered to the first surface of the nonwoven base layer. The coating layer includes a polymer material and a carrier composition. The composite nonwoven mat has an average Gurley porosity of at least 500 seconds.

Disclosed is a heat insulator comprising a substrate comprising of a bulk of silica-based inorganic fiber containing a hydroxyl group; a metallic or ceramic infrared mediator held on at least a part of one surface of the substrate; and a silica cured product holding the infrared mediator on/in the substrate. As the infrared mediator, a metal foil or a ceramic particle may be used. This heat insulator exhibits excellent heat insulating performance in a high temperature range of 600° C. or more, and can be molded into a three-dimensional shape which can be directly mounted to a structure.

Disclosed is a heat insulator comprising a substrate comprising of a bulk of silica-based inorganic fiber containing a hydroxyl group; a metallic or ceramic infrared mediator held on at least a part of one surface of the substrate; and a silica cured product holding the infrared mediator on/in the substrate. As the infrared mediator, a metal foil or a ceramic particle may be used. This heat insulator exhibits excellent heat insulating performance in a high temperature range of 600° C. or more, and can be molded into a three-dimensional shape which can be directly mounted to a structure.

A building wall includes an exterior surface and an interior surface. The exterior surface faces the exterior of the building and the interior surface faces an interior room of the building. The wall has a total wall thermal resistance between the exterior surface and the interior surface. The wall includes a structural member positioned between the exterior surface and the interior surface, and the structural member is configured to bear at least a portion of a vertical load of the wall. An insulated composite wall panel is positioned between the structural member and the interior surface. The insulated composite wall panel includes a skin layer including glass fibers and a cellulose fiber insulation board attached with a resin to a first surface of the skin layer. The thermal resistance of the cellulose fiber insulation board comprises the greatest component of the total wall thermal resistance.

A building wall includes an exterior surface and an interior surface. The exterior surface faces the exterior of the building and the interior surface faces an interior room of the building. The wall has a total wall thermal resistance between the exterior surface and the interior surface. The wall includes a structural member positioned between the exterior surface and the interior surface, and the structural member is configured to bear at least a portion of a vertical load of the wall. An insulated composite wall panel is positioned between the structural member and the interior surface. The insulated composite wall panel includes a skin layer including glass fibers and a cellulose fiber insulation board attached with a resin to a first surface of the skin layer. The thermal resistance of the cellulose fiber insulation board comprises the greatest component of the total wall thermal resistance.

Porous, binderless ceramic surface modification materials are described, and applications of use thereof. The ceramic surface material is in the form of an interconnected network of porous ceramic material on a substrate. The ceramic material may include a metal oxide, a metal hydroxide, and/or hydrates thereof, or a metal carbonate or metal phosphate, on a substrate surface. The substrate may be in the form of a metal or polymer particulate, powder, extrudate, or flakes.

The disclosure provides basemats for fibrous panels, including a mineral wool present in an amount of at least about 60 wt %, based on the total weight of the basemat, a mineral filler, a cellulose present in an amount of about 1 wt % to about 3 wt %, based on the total weight of the basemat, and a binder. The basemat has a backing side and a facing side. Also provided are fibrous panels including the basemat of the disclosure and a porous veil.