Abstract: A non-woven matrix of glass fibers, synthetic and natural fibers provides a rigid but resilient product having good strength and insulating characteristics. The product may be utilized in a planar configuration or be further formed into complexly curved and shaped configurations. The matrix consists of glass fibers, synthetic fibers such as polyester, nylon or Kevlar and natural fibers of wood or textiles which have been intimately combined with a thermosetting resin into a homogeneous mixture. This mixture is dispersed to form a blanket. A variety of products having varying thickness and rigidity may then be produced by controlling the compressed thickness and the degree of activation of the thermosetting resin. The product may also include a skin or film on one or both faces thereof. An alternate embodiment includes a conductive/coloring agent such as carbon black.

Abstract: A non-woven matrix of sized bushing glass and synthetic fibers provides a rigid but resilient product having good strength and insulating characteristics. The product finds particular application in large area panels such as vehicle headliners. The matrix consists of glass fibers, first, solid or hollow homogeneous synthetic fibers such as polyester, nylon or Kevlar and second, bi-component synthetic fibers which have been intimately combined with a thermosetting resin into a homogeneous mixture. The bi-component synthetic fibers include an outer low melting temperature sheath and a higher melting temperature core. This mixture is dispersed to form a blanket. The blanket may be heated and pressed to cure and form it into a final product in one step on two steps. In the one step process, the curing temperature is sufficiently high to melt the sheath of the bi-component fibers and activate and cure the thermosetting resin.

Abstract: A non-woven matrix of glass and synthetic fibers provides a rigid but resilient product having good strength and insulating characteristics. The matrix consists of glass fibers, first, solid or hollow homogeneous synthetic fibers such as polyester, nylon or Kevlar and second, bi-component synthetic fibers which have been intimately combined with a thermosetting resin into a homogeneous mixture. This mixture is dispersed to form a blanket. The bi-component synthetic fibers include an outer low melting temperature sheath and a higher melting temperature core. Initial curing of the fiber matrix entails melting and subsequent fiber bonding by the material of the sheath. Final curing entails activation of the thermosetting resin. The product may be utilized in a planar configuration or be further formed into complexly curved and shaped configurations. The product may also include a skin or film on one or both faces thereof.

Abstract: A non-woven matrix of mineral fibers and man-made fibers provides a rigid but resilient product having good strength and insulating characteristics. The product may be utilized in a planar configuration or be further formed into complexly curved and shaped configurations. The matrix consists of glass fibers and synthetic fibers such as polyester, nylon or Kevlar which have been shredded and intimately combined with a thermosetting resin into a homogeneous mixture. This mixture is dispersed to form a blanket. A variety of products having varying thickness and rigidity may then be produced by controlling the compressed thickness and the degree of activation of the thermosetting resin. The product may also include a skin or film on one or both faces thereof.