Abstract: A composite laminate or layer structure includes a substrate (2) and a cover layer (4) bonded thereon. The substrate is made up of at least one layer (3) of fiber-reinforced synthetic material. The cover layer includes at least one layer (5) of metal fibers and/or threads (6), and a metal sheet (7) forming the outer surface skin (8) of the layer structure. The metal sheet is bonded by soldering or sintering onto the metal fibers and/or threads (6), while the layer of metal fibers and/or threads in turn is bonded to the underlying fiber-reinforced synthetic material (3) by being mutually and integrally permeated by a synthetic resin matrix and bonding material. Also, the metal fibers and/or threads (6) may be intermeshed with the fibers of the synthetic material (3).

Abstract: Described are microfiber articles and methods and intermediates for their production, the microfiber articles being preferably produced from co-extruded microlayer films, and the articles having a microlayer construction that allows selection of the different layers to have different properties such that the article can have a desired combination of properties.

Abstract: A mirror structure includes a plurality of features of a defined size. The features include alternating spatial units of a chalcogenide glass and a thermoplastic polymer, and are specifically arranged in an ordered form so that the structure is highly reflective. Thermally-assisted methods are introduced for forming such structures.

Abstract: The present invention relates to a construction material for vehicles which material consists of a formable sandwich material which comprises at least two plates (1, 2) with intermediate fibres (5) which are arranged on at least one of the plates (2) by means of electrostatic deposition and the invention whereby the fibres (5) consist of metallic material.

Abstract: A non-asbestos-based friction material for brakes, clutches or the like for automobiles, large-size trucks, railway cars and various industrial machines. The friction material has excellent friction and rust preventive characteristics, and attacks the plane it faces to a limited extent. The non-asbestos-based friction material is produced by forming and then curing the non-asbestos-based friction material composition comprising a fibrous base, binder and filler as the major ingredients. The composition contains at least one type of steel fibers selected from the group consisting of iron, special dead soft steel and dead soft steel, containing carbon (C) at 0.13% or less at specific contents, in the fibrous base at 1 to 50% by volume of the whole friction material.

Abstract: This invention is to provide an automobile interior headliner molding or forming member which has high rigidity, being excellent in heat resistance and size stability, and having excellent moldability or formability. An automobile interior headliner molding or forming member is produced using a seven-layer polypropylene foam laminate obtained by stacking, over both sides of a foamed polypropylene sheet, a glass fiber sheet laminate, which has been obtained by laminating a polypropylene sheet with both sides of a glass fiber sheet.

Abstract: This invention is directed to a reinforced adhesive fiber that includes a pressure sensitive adhesive component and a reinforcing material within the pressure sensitive adhesive component.

Abstract: This invention relates to bioabsorbable fibers, comprising a semicrystalline fiber-forming core polymer and an amorphous sheath polymer, wherein the core polymer and sheath polymer are separately melt extruded and connected to one another through an adhesive bond. The present invention also relates to reinforced composites of the bioabsorbable fibers, and to devices comprising the reinforced composites. The devices are suitable for in vivo implantation. Some embodiments of the present devices can also support high loads, making then useful for fracture fixation and spinal fusion. The invention also relates to methods of making the various materials of the invention.

Abstract: A floor covering is described having a point-bonded nonwoven upper fabric layer and at least one backing layer. The floor covering has excellent abrasion and wear resistance. An antistatic floor covering comprising a point-bonded nonwoven upper fabric layer is also described.

Abstract: A reinforced vitreous carbon composite suitable for use in the formation of wear-resistant assemblies, such as joint prosthetic devices, bearings, current collectors, sealing components, brake linings, electrical motor brushes, and other tribological products. The reinforced composite is formed by impregnating a metal reinforcement structure with a furfuryl alcohol resin, and polymerizing the resin while thermally managing the polymerization process, to produce a poly(furfuryl) alcohol continuous phase that is isotropic, homogeneous and essentially completely void-free, e.g., in a bulk composite form having dimensions greater than 25 millimeters in each of the x, y and z directions thereof.

Abstract: A water-borne resin composition which can be readily applied to treat fibrous substrates at ambient temperatures and which provides enhanced strength and rigidity for the substrate under both ambient as well as wet or humid conditions is provided. Preferably, paper substrates treated with the resin are capable of being repulped and recycled.

Abstract: Multilayer composite materials with at least one aerogel-containing layer and at least one layer containing polyethylene terephthalate fibres, process for producing the same and their use.

Abstract: A three-dimensional weave architecture for weaving preforms has fill fibers woven to provide layer-to-layer interlocking of layers of warp fiber as well as interlocking of fibers within each layer. The woven preform transfers out-of-plane loading through directed fibers to minimize inter-laminar tension. The preform has a base and at least one leg extending from the base, the base and leg each having at least two layers of warp fibers. The fill fibers follow a weave sequence which carries them through part of the base, then into the legs, then through the other portion of the base, and back through the base to return to the starting point of the fill tow. The leg may be connected at a single- or distributed-column intersection, and the intersection may be radiussed. The outer ends of the base and legs may have tapers formed from terminating layers of warp fibers in a stepped pattern.

Abstract: Described are microfiber-entangled products and methods of producing microfiber-entangled products from microfiber materials or microfiber-forming materials, the microfiber entangled products having various useful product constructions that incorporate microfiber materials and other materials that can be combined by folding, weaving, lapping, twisting, tying, braiding, or otherwise.

Abstract: A substrate fiber for a dry friction material includes a trunk portion extending in the axial direction of the fiber and divergent portions slightly diverged from a part of the trunk portion and having small diameters. The diameter of the trunk portion is from about 10 to 20 &mgr;m and the length of the trunk portion is from about 0.5 to 5 mm.

Abstract: In an overlay trim member for, for example, the dashboard or other portion of an automobile, truck, recreational vehicle or as the case may be there is a main plate having at least one opening therein, and at least one insert plate which has a shape and dimensions corresponding to those of the opening in the main plate and is snugly disposed within the opening, the main plate and the insert plate being mounted on double-sided adhesive tape by which the overlay trim member may be operatively attached to the dashboard or other desired portion. The material or finish of the insert plate differs from that of the main plate thereby to provide enhancement of the aesthetic appearance of the overlay trim member.

Abstract: The present invention relates to high quality composite materials from fibrous materials, in which the composite incorporates a polymer matrix embedding individual fibers. The matrix is derived from polymer particles which penetrate into a strand and substantially fill gaps between individual fibers. Such penetration can occur by exposing the strand to a stable emulsion of the polymer particles. The invention also relates to novel composite structures which incorporation of various types of fibrous segments. These composite structures allow the use of inexpensive and readily available scrap materials. The composites of the present invention are lightweight materials displaying enhanced strength and durability.

Abstract: A composite with a thermoplastic matrix and fiber reinforcement is made by rotation of an exit die about a roving of continuous fiber in the presence of a thermoplastic melt. The rotation causes opposing inner and outer helical flow conditions which reduce the melt viscosity of the polymer by shear thinning while dragging and directing the polymer into the fiber roving thereby wetting and dispersing the fiber. A composite structure is formed with a polymer rich skin and a core region of unidirectionally aligned polymer and fiber. The polymeric skin is composed of helically aligned polymer chains which are coiled by the rotation around the core to compress the core region and enhance fiber wet out.

Abstract: Charged, high-strength, high-modulus, melt-processed microfibers, films having a charged, microfibrillated surface, and methods of making the same are described. Charged microfibrillated articles of the invention can be prepared by imparting fluid energy, typically in the form of high-pressure waterjets, to a highly oriented, highly crystalline, melt processed film to liberate microfibers or microfibrous flakes therefrom. Microfibrillated articles of the invention find use as tape backings, in the preparation of woven or nonwoven articles, filters for particulate contaminants, such as face masks and water or air filters, fibrous mats, such as those used for removal of oil from water, wipes for dust or debris removal, and thermal and acoustical insulation.

Abstract: A conductive carbonaceous-fiber sheet has a thickness of from 0.05 to 1 mm, a weight per a unit area of from 60 to 250 g/m2, a bending resistance (L) as determined by the 45° Cantilever method of 6 cm or higher and an in-plane volume resistivity of 0.2 &OHgr;cm or lower, and is suitable for use as a gas diffusion layer in a solid polymer electrolyte fuel cell.

Abstract: A reinforcing lamina sheet and a process of making a reinforcing sheet for use in a glue laminated beam. The reinforcing lamina sheet increases the compressive and/or tensile strength of the glue laminate beam. The lamina sheet is formed from unidirectionally oriented reinforcing filaments, preferably aramid filaments in an epoxy resin, and is cured in a curved configuration. The resulting lamina sheet includes filaments which are uniformly tensioned and, therefore, when a load is applied to the glue laminate beam having the reinforcing lamina sheet, the fibers receive the load substantially simultaneously. The process of forming the lamina sheet includes drawing reinforcement yarns through a resin bath to form a resin impregnated substantially planar yarn band, contacting one side of the resulting impregnated band with a curved heated surface to promote partial curing of at least the contacting surface of the band, and further applying heat to at least the opposite side of the partially cured band.

Abstract: A liner for a high pressure gas container includes a resin composition containing a polyphenylene sulfide resin and an olefin based resin. The resin composition has a methane gas permeability coefficient of 1.7×10−16 mol·m/m2·s·Pa or smaller at 40° C., and tensile elongation of 50% or greater after fracture at 23° C. A high pressure gas container having such a liner is also provided.

Abstract: An electrical insulating vapor grown carbon fiber containing a vapor grown carbon fiber having a fiber diameter of 0.01 to 0.5 &mgr;m, wherein the surface thereof is partially or entirely coated with an electrical insulating material and a method of producing thereof is disclosed.

Abstract: The present invention is directed to water-dispersible polymers. The present invention is also directed to a method of making water-dispersible polymers and their applicability as binder compositions. The present invention is further directed to fiber-containing fabrics and webs comprising water-dispersible binder compositions and their applicability in water-dispersible personal care products.

Abstract: A melt-infiltrated, fiber-reinforced composite ceramic containing high-temperature-resistant fibers, in particular fibers based on Si/C/B/N, which are reaction-bonded to a matrix based on Si and also a process for producing such a composite ceramic are described. The silicon melt which is used for the melt infiltration contains additions of iron, chromium, titanium, molybdenum, nickel or aluminum, with particular preference being given to a silicon melt containing from about 5 to 50 % by weight of iron and from about 1 to 10% by weight of chromium. This gives a simplified production process compared with conventional silicon melt infiltration and improved properties of the composite ceramic.

Abstract: The present invention relates to a molded article laminated with fabric wherein a thermoplastic resin (A) has a fabric, made up of fibers of a highly heat resisting thermoplastic resin (B), adhered to the surface thereof, wherein the thermoplastic resin (A) of the molding contains the highly heat resisting thermoplastic resin (B) constituting the fibers and wherein the highly heat resisting thermoplastic resin (B) is present as minute particles in the thermoplastic resin (A), and a method not only for reprocessing the mold flashes at the time of the preparation of molded articles laminated with fabric but also for reprocessing the defective molded articles laminated with fabric which come from the production line and are destined to be discarded.

Abstract: Fibrous monolith processing techniques to fabricate multifunctional structures capable of performing more than one discrete function such as structures capable of bearing structural loads and mechanical stresses in service and also capable of performing at least one additional non-structural function.

Abstract: Polymer resin/dispersed modifier compositions are provided. The polymer resin/dispersed modifier compositions have improved melt processability and properties and may be used to thermally process films, fibers, and articles having improved properties. In one embodiment, the polymer resin/dispersed modifier compositions are further grafted with one or more monomers, which graft onto the polymer resin and/or the dispersed modifier. In a further embodiment, the polymer resin is a water-soluble or water-dispersible polymer, such as polyethylene oxide; the modifier is a styrene butadiene polymer, a carboxylated acrylonitrile-butadiene-styrene polymer, or a combination thereof; and the grafted monomer is poly(ethylene glycol) ethyl ether methacrylate, poly(ethylene glycol) ethyl ether acrylate, 2-hydroxyethyl methacrylate (HEMA), poly(ethylene glycol) methacrylate (PEG-MA), or a mixture thereof.

Abstract: Bodies made of expanded graphite are impregnated with low-viscosity, solvent-free, storage-stable, polymerizing acrylic resins up to resin contents of 50% by weight. A primary product made of expanded graphite has an open pore system, with a particularly preferred range of bulk densities of from 0.5 to 1.3 g/cm3 and with an ash value of not more than 4% by weight. Such bodies can also contain a proportion of additives. The impregnated, shaped and rapidly curable graphite bodies are employed as sealing elements, as components in fuel cells or as heat-conducting elements. A process for producing the bodies is also provided.

Abstract: A friction material for brake including reinforcing fibers, a friction modifier, a lubricant, and a binder, characterized by containing, as a part of the component of the friction modifier, 2 to 5 wt % zeolite, 0.8 to 2 wt % antimony oxide and 0.2 to 1 wt % fluorine based polymer.

Abstract: A protective covering system having high-flexibility and low areal density characteristics. In one aspect of the invention, the protective system includes a plurality of metallic staples or wire elements secured to multi-layer matrix including woven fibers, the layers being oriented at cross angles to provide a grid-like pattern of protective elements. In one aspect of the invention, protective elements provide a coverage area of less than 90% and as little as 40% of total surface area. In one aspect of the invention, protective elements may be mechanically secured to a matrix by a puncture and crimp process. In another, wire elements may be attached or woven into one or more matrix layers.

Abstract: This invention provides a composite material having a matrix of structural material containing embedded zones of soft elastic material and zones of solid relatively high density material within the soft elastic material. By selecting a particular resonance frequency for the subunits of soft elastic material and solid high density material, frequencies just lower than the resonance frequencies will be unable to propagate through the material and be strongly reflected or absorbed. Such material may be used in the manufacture of filters or shields against particular target frequencies. Subunits having a variety of resonance frequencies may provide a broader range of frequencies that the material may shield.

Abstract: An asphalt-based roofing material includes a substrate coated with an asphalt coating, a protective coating adhered to the upper surface of the asphalt coating, a layer of granules adhered to the protective coating, and a web bonded to the lower region of the asphalt coating. A method of manufacturing a roofing material includes coating a substrate with an asphalt coating, applying a protective coating to the upper surface of the asphalt coating, applying a layer of granules to the protective coating, and applying a web to the lower region of the asphalt coating.

Abstract: The present invention relates to electrically conductive impregnated fibers and their method of manufacture. More particularly, the invention relates to a method for forming electrically conductive fibers by impregnating conductive fibers with an organic wetting agent to form an impregnated fiber tow and subsequently sheathed. Such sheathed impregnated tows can be formed into a wide variety of products such as radio-frequency and electromagnetic shielded plastic articles.

Abstract: A stretchable conveyor belt having a plurality of first cuts which extend in a widthwise direction of the belt, which extend from one of opposite surfaces of the belt toward the other surface thereof and do not reach said other surface, and which are provided at a regular interval of distance in a lengthwise direction of the belt, and/or a plurality of second cuts which extend in the widthwise direction of the belt, which extend from said other surface of the belt toward said one surface thereof and do not reach said one surface, and which are provided at a regular interval of distance in the lengthwise direction of the belt, the first cuts and/or the second cuts providing a stretchability of the belt.

Abstract: A fibrous high temperature pressed rigid board is made using alumina silica fiber, soluble fiber (so-called green fiber or body fluid soluble fiber) or mineral wool or a combination of two or more of the above fiber types. The board is made by adding a water soluble, inorganic, granular/powder binder to the fiber at a point in the process between the fiber collection chamber and the blowing nozzle or spinning apparatus so that the binder is dispersed throughout the fiber as the continuous fleece or blanket is being produced. The fiber can also be accumulated on a wheel until the desired thickness or basis weight is achieved. The fleece is cut into a predetermined size and is then subjected to the application of water spray and placed into a hot press at a temperature sufficient to cause the water to heat and produce steam which rapidly dissolves the binder within the fleece and left in the press until dry or nearly dry.

Abstract: A method of manufacturing articles utilizing a composite material having a high density of small particles such as microspheres in a matrix material is disclosed. In accordance with one aspect of the present invention, at least first and second layers of flanking material are disposed in a generally non-parallel relationship with respect to each other and then are pulled through a die. While the flanking material layers are being pulled through the die, a composite material is injected into a space defined between the at least first and second layers of flanking material. The composite material and the at least first and second layers of flanking material are heated as they pass through the die to cure the composite material and bond the at least two flanking material layers to the composite material, thereby forming a cured article.

Abstract: Aerogel composite materials having a lofty fibrous batting reinforcement preferably in combination with one or both of individual short randomly oriented microfibers and conductive layers exhibit improved performance in one or all of flexibility, drape, durability, resistance to sintering, x-y thermal conductivity, x-y electrical conductivity, RFI-EMI attenuation, and/or burn-through resistance.

Abstract: In this tape (15), the fibers are discontinuous and have a length distribution such that the mean fiber length, that is to say the mean length of 50% of the fibers in a specimen, is between approximately 40 and 70% of the length of the longest fiber in the specimen, the fibers being combined by means of a resin (10) or of an adhesive having a fugitive nature. Application to the production of components made of composites.

Abstract: The present invention relates to cellulosic substrates with reduced absorbent capacity having the capability to wick liquids, as well as to methods of manufacturing such cellulosic substrates. The cellulosic substrates provided by the present invention comprise an inside and an outside connected to the inside. The inside comprises cellulosic fibers and has a reduced absorbent capacity, and the outside comprises cellulosic fibers. The outside may have a reduced absorbent capacity and may have an absorbent capacity higher than the inside. The cellulosic substrate is capable of wicking liquid contacting the inside of the substrate to the outside of the substrate.

Abstract: A composite material having a preferably rigid preformed ceramic fiber matrix at least partially impregnated with an aerogel and forming a multi-layered material. The matrix is impregnated with an aerogel material which forms a layer having a total thickness r where r is less than t or equal to t, where t is the thickness of the matrix, thus forming a single or multilayered composite material. The material may be formed with numerous layers s1, s2, S3, . . . snn where r=&Sgr;sn and r is less than or equal to t. Thus, a multi-layered material is formed. Alternatively, the aerogel/fiber matrix composite has channels devoid of aerogel.

Abstract: A method of manufacturing articles utilizing a composite material having a high density of small particles such as microspheres in a matrix material is disclosed. In accordance with one aspect of the present invention, at least first and second layers of flanking material are disposed in a generally non-parallel relationship with respect to each other and then are pulled through a die. While the flanking material layers are being pulled through the die, a composite material is injected into a space defined between the at least first and second layers of flanking material. The composite material and the at least first and second layers of flanking material are heated as they pass through the die to cure the composite material and bond the at least two flanking material layers to the composite material, thereby forming a cured article.

Abstract: An exterior automotive quality paint coat is laminated to the surface of a plastic car body member of panel. A dry paint transfer film is first laminated to a relatively thin semi-rigid thermoformable resinous backing sheet. The backing sheet side of the resulting laminate is then laminated to a relatively thick thermoformable substrate sheet comprising the same or a compatible polymeric material. The two sheets are joined by extruding the thick substrate sheet and using the heat of extrusion to then laminate the thin backing sheet to the thicker extruded substrate sheet. The resulting thick sheet laminate is then thermoformed, preferably by first heating the laminate to a forming temperature, followed by vacuum forming the laminate to a three-dimensional shape of the finished automotive part, such as a facia, ready to put on a vehicle.

Abstract: A ligneous finishing material including a base plate, a sheet formed from a sheet base impregnated with a thermosetting resin and attached to the base plate, and a decorative sheet impregnable with a resin and attached to the sheet. The base plate, sheet and decorative sheet are laminated on each other by a hot-press process. The thermosetting resin is preferably a phenol resin having a fluidity in a pre-pregnated state of 3% to 50%. The ligneous finishing material is inexpensive and highly resistant to surface damaging, and can be used as a surface facing material for floors, etc., and as a facing material for fittings and furnishings.

Abstract: A composition containing a function improver and an inorganic porous crystals-hydrophilic macromolecule composite wherein the hydrophilic macromolecule contains inorganic porous crystals in its inner matrix, and a product made therefrom The product, textile, nonwoven fabric, paper and laminate obtained from the composition of the present invention come to have high strength in addition to the gas adsorption capability, volatile organic solvent removing capability, noncombustibility, heat insulating property, and heavy metal and radioactive element removing capability that the inorganic porous crystals-hydrophilic macromolecule composite (A) possesses. It is also possible to improve a touch and the like, so that the composition is useful as a material having additional functions.

Abstract: A thermoformable laminate including a rigid thermoplastic foam sheet and a fiber reinforcing layer adhered to each of two opposite faces of the rigid thermoplastic foam sheet is heated to the thermoforming softening temperature of the rigid thermoplastic foam sheet, and shaped and compressed to form a headliner having varying thicknesses, including a major portion of the headliner which is relatively thin and highly compressed, and at least one relatively thick, lightly compressed or non-compressed impact absorption area. The thermoformable laminate and method make it possible to form a headliner with integral impact absorption areas from a laminate of uniform thickness and density, using a single thermoforming operation.

Abstract: A non-asbestos friction material includes a fibrous reinforcement, a friction modifier, a binder, and a soluble amorphous substance mixed as friction material components. The soluble amorphous substance is a composition composed of SiO2 as a principal component, 18 to 40 wt % of at least one kind of CaO and MgO, less than 10 wt % of at least one kind of Al2O3 and ZrO2, and less than 2 wt % of at least one kind of Na2O, K2O, FeO and Fe2O3. Preferably, the soluble amorphous substance is mixed in a range of from 1 wt % to 30 wt % of a total of the friction material. Preferably, the soluble amorphous substance is fibrous or granular.

Abstract: An exterior autobody part of reinforced plastic intended to be mounted on a motor vehicle. The expression “exterior autobody part” refers to the autobody part being entirely or partly visible when the motor vehicle is viewed from the outside. Furthermore, the invention relates to a method and an arrangement for forming such an exterior autobody part. The exterior autobody part according to the invention comprises a number of functional layers, including load-bearing layer(s) and surface layer(s), intended to provide the properties which are required for the application, and is characterized in that load-bearing layers comprise(s) fiber-reinforced thermoplastic which forms internal cavities and/or that one or several recesses has/have been created in surface layers and load-bearing layers and that surface layers and load-bearing layers together with cavities and/or recesses thereby provide a load-bearing material structure.

Abstract: A moisture barrier paper is comprised of a fiber mat and a unique moisture barrier coating. The moisture barrier coating coats substantially every fiber throughout the fiber mat. The moisture barrier paper is created in a wet-end, on-machine process where a liquid, moisture barrier coating is sprayed onto a forming fiber mat and is drawn through the fibers with vacuum. The moisture barrier paper has top and bottom surfaces that are substantially free of wax and polymeric water repellants. The moisture barrier paper is completely repulpable.

Abstract: In a structural element of high unidirectional rigidity, in which unidirectional fiber strands are completely embedded in sheaths and said sheaths are connected to a shell skin and wherein part of the shell skin is in the form of stringers, there is provided an inner division of the cross-section of the shell skin thereby providing the strength of the fibers and the stiffness of the fibers in a direction perpendicular to the skin plane for every direction of loading.