Abstract: The invention relates to the manufacture of new composite materials suitable in particular as materials in interior construction, for linings, constructions and for the manufacture of furniture and similar products.

Abstract: The invention relates to directly decoratable and/or printable composite materials suitable in particular as materials in interior finishing, for linings, constructions and for the manufacture of furniture and similar products.

Abstract: A multilayer fibrous nonwoven mat containing at least one transition zone comprised of a mixture of the slurries used to form the layers on each side of the transition zone, the transition zone having a thickness of at least 1 percent of the thickness of the mat. At least one of the layers contains glass fibers. The multilayer mats are particularly useful as facers on gypsum wall board, insulating foam, a wood material and a broad range of other materials. The multilayer mats are made by a method that involves using a lamella in the forming box on a wet laid mat machine, between slurries, the lamella ending a significant distance prior to a moving forming wire. The transition zone or zones provide superior interlaminar shear strength and other properties compared to multilayer fibrous mats produced on wet laid machines having two or more separate forming boxes.

Abstract: Making mats using glass fibers having a diameter of about 13+/?3 microns, bound with a binder formed from a homopolymer or a copolymer of polyacrylic acid and a polyol produces fibrous nonwoven mats having high tensile strength and also an unexpected high flame resistance considering the amount of oxygen in the binder. Mats of the present invention pass the National Fire Protection Association's (NFPA) Flammability Test. Tabor stiffness of these mats is greater than about 40, preferably greater than about 50 and most preferably greater than about 55. Air permeability of the mats is preferably within the range of about 500 to about 800 CFM/sq. ft. Methods of making the mat are also disclosed.

Abstract: Fibrous nonwoven mats comprising polyetherimid fibers and a binder comprising a resin and an adhesion promoter, and method of making the mat are disclosed. These mats have several uses and are particularly suited as facer mats for fiber reinforced thermoplastic thermoformable materials. When used as a facer, the mat bonds to the thermoformable material and provides a resin rich outer layer and facilitates bonding to a decorative cover.

Abstract: A multilayer fibrous nonwoven mat containing at least one transition zone comprised of a mixture of the slurries used to form the layers on each side of the transition zone, the transition zone having a thickness of at least 1 percent of the thickness of the mat. At least one of the layers contains glass fibers. The multilayer mats are particularly useful as facers on gypsum wall board, insulating foam, a wood material and a broad range of other materials. The multilayer mats are made by a method that involves using a lamella in the forming box on a wet laid mat machine, between slurries, the lamella ending a significant distance prior to a moving forming wire. The transition zone or zones provide superior interlaminar shear strength and other properties compared to multilayer fibrous mats produced on wet laid machines having two or more separate forming boxes.

Abstract: A new foam coated nonwoven fibrous mat having properties particularly suited for a facer on gypsum wallboard, laminates made therefrom and the method of making the mat is disclosed. The mat preferably contains a major portion of glass fibers and a minor portion of a resinous binder. The foam coating is permeable and reduces fiber dust and abrasion experienced in the past with relatively coarse, relatively inexpensive glass fibers in the mat. Contrary to previous methods, the foam coated fibrous mat is made in-line on a wet mat forming production line by applying a wet foam binder onto a wet, fibrous web followed by drying and curing in-line.

Abstract: Fibrous nonwoven mats comprising polyetherimid fibers and a binder comprising a resin and an adhesion promoter, and method of making the mat are disclosed. These mats have several uses and are particularly suited as facer mats for fiber reinforced thermoplastic thermoformable materials. When used as a facer, the mat bonds to the thermoformable material and provides a resin rich outer layer and facilitates bonding to a decorative cover.

Abstract: Fibrous, nonwoven mats are disclosed that are bound with a formaldehyde-free, heat resistant resin in direct contact with the fibers. The heat resistant resin is capable of withstanding coating with a hot, molten material like asphalt or a mixture containing asphalt having a temperature of at least about 300 degrees F. and up to 450 degrees F. or higher. The preferred heat resistant resins are epoxies and urethanes, or mixtures thereof. The methods of making these mats with wet processes are also disclosed.

Abstract: A method of making a laminate product is provided. The method comprises (a) providing a furnish comprising wood particles and a binder and (b) providing at least one nonwoven fabric mat. A composite mat is formed using the furnish and the nonwoven fabric mat. The composite mat comprises: (1) a mat formed from the furnish, the mat having a first face and a second face, and (2) the nonwoven fabric mat contacting the first face of the mat formed from the furnish. The composite mat is subjected to sufficient heat and pressure to form a laminate product comprising a wood product panel having a first face, a second face, and edges with the nonwoven fabric mat adhered to the first face of the wood product panel.

Abstract: The present invention relates to laminate products comprising a non-wood cellulosic panel with at least one nonwoven fabric mat adhered thereto as well as to methods of making such laminate products.

Abstract: The present invention relates to methods of providing water protection to roof structures as well as the improved roof structures formed by the methods. The methods comprise providing one or more water resistant roof sheathing panels and installing the roof sheathing panel(s) on a roof structure of a building. Each of the roof sheathing panels comprises a wood sheet product and a nonwoven fabric mat adhered to at least one side of the wood sheet product.

Abstract: The present invention relates to methods of providing water protection to floor structures as well as the improved floor structures formed by the methods. The methods comprise providing one or more water resistant floor sheathing panels and installing the floor sheathing panel(s) on a floor structure of a building. Each of the floor sheathing panels comprises a wood sheet product and a nonwoven fabric mat adhered to at least one side of the wood sheet product.

Abstract: The present invention relates to methods of providing water protection to exterior and interior wall structures as well as the improved wall structures formed by the methods. The methods comprise providing one or more water resistant wall sheathing panels and installing the wall sheathing panel(s) on a wall structure of a building. Each of the wall sheathing panels comprises a wood sheet product and a nonwoven fabric mat adhered to at least one side of the wood sheet product.

Abstract: A system and method for designing a fibrous non-woven mat production, where the method includes selecting various physical characteristics for at least some of the components to be included in the mat, obtaining empirical performance data relating to the mat based on the selected physical properties, developing a prediction equation for a performance characteristic of the mat based on the empirical data and the physical characteristics, calculating performance characteristics using the prediction equation, where ranges of at least some of the physical characteristics are used in the prediction equation, and selecting components for the mat based on the calculated performance characteristics.

Abstract: A new foam coated nonwoven fibrous mat having properties particularly suited for a facer on gypsum wallboard, laminates made therefrom and the method of making the mat is disclosed. The mat preferably contains a major portion of glass fibers and a minor portion of a resinous binder. The foam coating is permeable and reduces fiber dust and abrasion experienced in the past with relatively coarse, relatively inexpensive glass fibers in the mat. Contrary to previous methods, the foam coated fibrous mat is made in-line on a wet mat forming production line by applying a wet foam binder onto a wet, fibrous web followed by drying and curing in-line.

Abstract: New coated nonwoven fibrous mats having properties particularly suited for a facer on gypsum wallboard and other substrates and in laminates of various types, and the method of making the coated mat is disclosed. The mat preferably contains a major portion of glass fibers and a minor portion of a resinous binder. The coating is preferably permeable and reduces fiber dust and abrasion experienced in the past with relatively coarse, relatively inexpensive glass fibers in the mat. Contrary to previous coating methods, the coated fibrous mat is made in-line on a wet mat forming production line by applying a wet foam binder onto a wet, fibrous web followed by drying and curing in-line.

Abstract: Methods of making nonwoven mats having good strength after being scored and folded and particularly useful in making lightweight, compressible ceiling panels are disclosed. The mats also have excellent flame resistance. The mats include a blend comprising a major portion of glass fibers and a minor portion of man-made polymer fibers, the fibers being bound together with a cured binder containing a homopolymer or copolymer of polyacrylic acid and a polyol. The binder bonding the mat together can be cured to only a “B” stage to produce thermoformable mats or more fully cured to produce mats having the properties described above.