Non-woven fibrous product

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. A conductive material in either particulate or fibrous form may be added to improve surface finish and, if desired and depending upon the choice of conductive material, darken the appearance of the product.

Dependencies are inferred from the claim text.