Abstract: Embodiments of the invention provide fiber mat facers, ceiling panels, and method of manufacturing the same. A fiber mat facer may include a non-woven web of fibers having a first group of fibers with an average fiber diameter from about 6 ?m to about 20 ?m and a second group of fibers with an average fiber diameter from about 0.5 ?m to about 5 ?m. The fiber mat facer may also include a binder to bond together the non-woven web of fibers into the fiber mat. The binder may include a water repellant additive. The binder and/or fiber mat facer may further include an additive that enhances the opacity of the fiber mat facer. The fiber mat facer may also include a paint applied to an outer surface of the facer. The paint may include an additive that enhances the visual appeal of the facer and/or ceiling panel.

Abstract: Glass-fiber composites are described that include a substrate containing glass fibers and particles in contact with the glass fiber substrate. The particles may include an alkali-metal containing compound. In addition, batteries are described with an anode, a cathode, and an electrolyte. The cathode may include alkali-metal containing nanoparticles in contact with glass fibers. Also describe are methods of making a glass-fiber composite. The methods may include the steps of forming a wet laid non-woven glass fiber substrate, and contacting alkali-metal containing particles on the substrate.

Abstract: Structural panels and methods of making composite material for such structural panels may include applying a resin to a nonwoven fibrous web, where the nonwoven fibrous web includes a combination of glass fibers and polymer fibers. The web may be dried at a first stage temperature at or below a curing temperature of the resin for a time sufficient to substantially dry but not substantially cure the resin. The web may be laminated at a second stage temperature sufficient to fully cure the resin to produce a composite material. The second stage temperature may be above the melting point of the polymer fibers, and the resin may cause the composite material to retain a substantially rigid shape upon completion of the laminating operation.

Abstract: Embodiments of the invention provide fiber mat facers, ceiling panels, and method of manufacturing the same. A fiber mat facer may include a non-woven web of fibers having a first group of fibers with an average fiber diameter from about 6 ?m to about 20 ?m and a second group of fibers with an average fiber diameter from about 0.5 ?m to about 5 ?m. The fiber mat facer may also include a binder to bond together the non-woven web of fibers into the fiber mat. The binder may include a water repellant additive. The binder and/or fiber mat facer may further include an additive that enhances the opacity of the fiber mat facer. The fiber mat facer may also include a paint applied to an outer surface of the facer. The paint may include an additive that enhances the visual appeal of the facer and/or ceiling panel.

Abstract: Embodiments of the invention provide fiber mat facers, ceiling panels, and method of manufacturing the same. A fiber mat facer may include a non-woven web of fibers having a first group of fibers with an average fiber diameter from about 6 ?m to about 20 ?m and a second group of fibers with an average fiber diameter from about 0.5 ?m to about 5 ?m. The fiber mat facer may also include a binder to bond together the non-woven web of fibers into the fiber mat. The binder may include a water repellant additive. The binder and/or fiber mat facer may further include an additive that enhances the opacity of the fiber mat facer. The fiber mat facer may also include a paint applied to an outer surface of the facer. The paint may include an additive that enhances the visual appeal of the facer and/or ceiling panel.

Abstract: Glass-fiber composites are described that include a substrate containing glass fibers and particles in contact with the glass fiber substrate. The particles may include an alkali-metal containing compound. In addition, batteries are described with an anode, a cathode, and an electrolyte. The cathode may include alkali-metal containing nanoparticles in contact with glass fibers. Described are methods of making a glass-fiber composite. The methods may include the steps of forming a wet laid non-woven glass fiber substrate, and contacting alkali-metal containing particles on the substrate.

Abstract: Structural panels and methods of making composite material for such structural panels may include applying a resin to a nonwoven fibrous web, where the nonwoven fibrous web includes a combination of glass fibers and polymer fibers. The web may be dried at a first stage temperature at or below a curing temperature of the resin for a time sufficient to substantially dry but not substantially cure the resin. The web may be laminated at a second stage temperature sufficient to fully cure the resin to produce a composite material. The second stage temperature may be above the melting point of the polymer fibers, and the resin may cause the composite material to retain a substantially rigid shape upon completion of the laminating operation.

Abstract: Structural panels and methods of making composite material for such structural panels may include applying a resin to a nonwoven fibrous web, where the nonwoven fibrous web includes a combination of glass fibers and polymer fibers. The web may be dried at a first stage temperature at or below a curing temperature of the resin for a time sufficient to substantially dry but not substantially cure the resin. The web may be laminated at a second stage temperature sufficient to fully cure the resin to produce a composite material. The second stage temperature may be above the melting point of the polymer fibers, and the resin may cause the composite material to retain a substantially rigid shape upon completion of the laminating operation.

Abstract: Glass-fiber composites are described that include a substrate containing glass fibers and particles in contact with the glass fiber substrate. The particles may include an alkali-metal containing compound. In addition, batteries are described with an anode, a cathode, and an electrolyte. The cathode may include alkali-metal containing nanoparticles in contact with glass fibers. Also describe are methods of making a glass-fiber composite. The methods may include the steps of forming a wet laid non-woven glass fiber substrate, and contacting alkali-metal containing particles on the substrate.

Abstract: Glass-fiber composites are described that include a substrate containing glass fibers and particles in contact with the glass fiber substrate. The particles may include an alkali-metal containing compound. In addition, batteries are described with an anode, a cathode, and an electrolyte. The cathode may include alkali-metal containing nanoparticles in contact with glass fibers. Described are methods of making a glass-fiber composite. The methods may include the steps of forming a wet laid non-woven glass fiber substrate, and contacting alkali-metal containing particles on the substrate.

Abstract: Glass-fiber composites are described that include a substrate containing glass fibers and particles in contact with the glass fiber substrate. The particles may include an alkali-metal containing compound. In addition, batteries are described with an anode, a cathode, and an electrolyte. The cathode may include alkali-metal containing nanoparticles in contact with glass fibers. Also describe are methods of making a glass-fiber composite. The methods may include the steps of forming a wet laid non-woven glass fiber substrate, and contacting alkali-metal containing particles on the substrate.

Abstract: Structural panels and methods of making composite material for such structural panels may include applying a resin to a nonwoven fibrous web, where the nonwoven fibrous web includes a combination of glass fibers and polymer fibers. The web may be dried at a first stage temperature at or below a curing temperature of the resin for a time sufficient to substantially dry but not substantially cure the resin. The web may be laminated at a second stage temperature sufficient to fully cure the resin to produce a composite material. The second stage temperature may be above the melting point of the polymer fibers, and the resin may cause the composite material to retain a substantially rigid shape upon completion of the laminating operation.

Abstract: A method of making a nonwoven fibrous mat that retains good strength and recovery after scoring and folding, properties making the mat useful in making collapsible ceiling tile. The mat comprises a majority of glass fibers and a minority of polymer fibers, the fibers being bound together with up to 35 wt. percent of a polyacrylic acid and polyol polymer binder based on the dry weight of the mat. The mat can be cured to “B stage”, thermoformed into the desired shape and then heated further to complete the cure of the binder.

Abstract: Embodiments of the invention provide fiber mat facers, ceiling panels, and method of manufacturing the same. A fiber mat facer may include a non-woven web of fibers having a first group of fibers with an average fiber diameter from about 6 ?m to about 20 ?m and a second group of fibers with an average fiber diameter from about 0.5 ?m to about 5 ?m. The fiber mat facer may also include a binder to bond together the non-woven web of fibers into the fiber mat. The binder may include a water repellant additive. The binder and/or fiber mat facer may further include an additive that enhances the opacity of the fiber mat facer. The fiber mat facer may also include a paint applied to an outer surface of the facer. The paint may include an additive that enhances the visual appeal of the facer and/or ceiling panel.

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: 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.

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.

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 gypsum board comprises a set gypsum layer having a first face and a second face. A fibrous mat is affixed to at least one of the faces. The mat comprises a non-woven web bonded together with a resinous binder. The web is composed of chopped continuous glass fibers having an average fiber diameter ranging from about 9.5 to 12.5 ?m. The board is exceedingly durable. It has a smooth surface that is readily finished in an aesthetically pleasing way, using paint or other wall covering systems.

Abstract: Alkaline resistant fibrous products containing a binder comprised of a blend of urea formaldehyde and melamine formaldehyde and having particular use in bonding to alkaline materials having a pH of about 8 or above, including cementitious boards and other shapes, to provide manufacturing aids, reinforcement, fire resistance and a smooth surface are disclosed. Laminates containing one or more of the alkaline resistant fibrous products, with fibers bonded together with melamine formaldehyde and optionally a blend of urea formaldehyde and melamine formaldehyde binder, in contact with at least one cementitious layer are disclosed. Also, methods of making the alkaline resistant fibrous products and laminates that contain one or more layers of the alkaline resistant fibrous products are disclosed.