A nonwoven mat and a method of making a nonwoven mat are provided. The nonwoven mat includes reinforcing fibers and a binder composition that includes a polycarboxy polymer and polymer microspheres. The binder composition may also include low-density fibers, such as microfibrillated cellulose fibers. The polymer microspheres have a thermoplastic shell that encapsulates a blowing agent. The thermoplastic shell has magnesium hydroxide on its outer surface. The components of the binder composition interact with one another and/or the reinforcing fibers to form a nonwoven mat having a less permeable structure and a higher caliper.

A nonwoven mat and a method of making a nonwoven mat are provided. The nonwoven mat includes reinforcing fibers and a binder composition that includes a polycarboxy polymer and polymer microspheres. The binder composition may also include low-density fibers, such as microfibrillated cellulose fibers. The polymer microspheres have a thermoplastic shell that encapsulates a blowing agent. The thermoplastic shell has magnesium hydroxide on its outer surface. The components of the binder composition interact with one another and/or the reinforcing fibers to form a nonwoven mat having a less permeable structure and a higher caliper.

A method for arranging nanotube elements within nanotube fabric layers and films is disclosed. A directional force is applied over a nanotube fabric layer to render the fabric layer into an ordered network of nanotube elements. That is, a network of nanotube elements drawn together along their sidewalls and substantially oriented in a uniform direction. In some embodiments this directional force is applied by rolling a cylindrical element over the fabric layer. In other embodiments this directional force is applied by passing a rubbing material over the surface of a nanotube fabric layer. In other embodiments this directional force is applied by running a polishing material over the nanotube fabric layer for a predetermined time. Exemplary rolling, rubbing, and polishing apparatuses are also disclosed.

A method for arranging nanotube elements within nanotube fabric layers and films is disclosed. A directional force is applied over a nanotube fabric layer to render the fabric layer into an ordered network of nanotube elements. That is, a network of nanotube elements drawn together along their sidewalls and substantially oriented in a uniform direction. In some embodiments this directional force is applied by rolling a cylindrical element over the fabric layer. In other embodiments this directional force is applied by passing a rubbing material over the surface of a nanotube fabric layer. In other embodiments this directional force is applied by running a polishing material over the nanotube fabric layer for a predetermined time. Exemplary rolling, rubbing, and polishing apparatuses are also disclosed.

A fabric of nanofibers that includes an adhesive is described. The nanofibers can be twisted or both twisted and coiled prior to formation into a fabric. The adhesive can be selectively applied to or infiltrated within portions of the nanofibers comprising the nanofiber fabric. The adhesive enables connection of the nanofiber fabric to an underlying substrate, even in cases in which the underlying substrate has a three-dimensional topography, while the selective location of the adhesive on the fabric limits the contact area between the adhesive and the nanofibers of the nanofiber fabric. This limited contact area can help preserve the beneficial properties of the nanofibers (e.g., thermal conductivity, electrical conductivity, infra-red (IR) radiation transparency) that otherwise might be degraded by the presence of adhesive.

A fabric of nanofibers that includes an adhesive is described. The nanofibers can be twisted or both twisted and coiled prior to formation into a fabric. The adhesive can be selectively applied to or infiltrated within portions of the nanofibers comprising the nanofiber fabric. The adhesive enables connection of the nanofiber fabric to an underlying substrate, even in cases in which the underlying substrate has a three-dimensional topography, while the selective location of the adhesive on the fabric limits the contact area between the adhesive and the nanofibers of the nanofiber fabric. This limited contact area can help preserve the beneficial properties of the nanofibers (e.g., thermal conductivity, electrical conductivity, infra-red (IR) radiation transparency) that otherwise might be degraded by the presence of adhesive.

Provided is a porous electrode substrate capable of reducing a drop in electromotive force when used in a battery. This porous electrode substrate comprises a carbon fiber sheet wherein carbon fibers are bound by a binder. For dust of 0.3 μm or more in particle size, the dust generation amount per 1 m.sup.2 of the porous electrode substrate is 120,000/m.sup.2 or less, as determined by the following method: dust particles in a gas obtained by suctioning at 47.2 mL/s for 40 minutes using a dust collecting hood having an opening of 500 mm×100 mm while traveling the sheet at a speed of 10 m/min from a position 200 mm below the sheet are used; the number of dust particles having a diameter within a predetermined range is measured by a particle counter; and the measured value is divided by 200 m.sup.2, which is a suction area, and the resulting value is defined as a dust generation amount per 1 m.sup.2.

Provided is a porous electrode substrate capable of reducing a drop in electromotive force when used in a battery. This porous electrode substrate comprises a carbon fiber sheet wherein carbon fibers are bound by a binder. For dust of 0.3 μm or more in particle size, the dust generation amount per 1 m.sup.2 of the porous electrode substrate is 120,000/m.sup.2 or less, as determined by the following method: dust particles in a gas obtained by suctioning at 47.2 mL/s for 40 minutes using a dust collecting hood having an opening of 500 mm×100 mm while traveling the sheet at a speed of 10 m/min from a position 200 mm below the sheet are used; the number of dust particles having a diameter within a predetermined range is measured by a particle counter; and the measured value is divided by 200 m.sup.2, which is a suction area, and the resulting value is defined as a dust generation amount per 1 m.sup.2.

Disclosed is a treatment agent for flame-resistant fiber nonwoven fabric production or for carbon fiber nonwoven fabric production. The treatment agent contains a polyether compound in which ethylene oxide and propylene oxide are added to an alcohol. Also disclosed is a flame-resistant fiber nonwoven fabric or carbon fiber nonwoven fabric that includes the treatment agent adhered thereto.

Disclosed is a treatment agent for flame-resistant fiber nonwoven fabric production or for carbon fiber nonwoven fabric production. The treatment agent contains a polyether compound in which ethylene oxide and propylene oxide are added to an alcohol. Also disclosed is a flame-resistant fiber nonwoven fabric or carbon fiber nonwoven fabric that includes the treatment agent adhered thereto.