Abstract: A method of improving filtration efficiency of a fibrous nonwoven filter media comprises providing a filter media and incorporating in the filter media one or more additives selected from the group consisting of silicone additives, wax additives, and mixtures thereof. The filter media comprises glass fibers, polymer fibers, and optionally binder. Inclusion of silicone and/or wax additive(s) in a filter media has surprisingly been found to increase filtration efficiency, for example, by 10-15%.

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: 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 comprises a blend of a major portion composed of chopped continuous glass fibers having an average fiber diameter ranging from about 8 to 17 ?m and a minor portion composed of fine staple fibers having an average fiber diameter of less than about 5.5 ?m, the minor portion comprising about 1-30 percent of the dry weight of the web. 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.

Abstract: A method of improving filtration efficiency of a fibrous nonwoven filter media comprises providing a filter media and incorporating in the filter media one or more additives selected from the group consisting of silicone additives, wax additives, and mixtures thereof. The filter media comprises glass fibers, polymer fibers, and optionally binder. Inclusion of silicone and/or wax additive(s) in a filter media has surprisingly been found to increase filtration efficiency, for example, by 10-15%.

Abstract: Wet laid, nonwoven, fibrous mats suitable for making MERV 6 or higher filters, and methods of making the nonwoven mats are disclosed. The mats include a blend comprising a major portion of glass fibers and a minor portion of man-made polymer fibers, such as polyester fibers, the fibers being bound together with a cured binder having a Tg in the range of about minus 30 to about 50 degrees C. The mats are pleated prior to assembling the filter in conventional manner. The only fibrous mat in the filters is wet laid fibrous nonwoven mat and the pleated filter media needs no other means of support in the filter frame.

Abstract: Wet laid, nonwoven, fibrous mats suitable for making MERV 6 or higher, filters, and methods of making the nonwoven mats filter media are disclosed. The mats include a blend comprising a major portion of glass fibers, a minor portion of man-made polymer fibers, such as polyester fibers and about 0-30 wt. percent of chemically cross linked bleached Kraft pulp the fibers, and optionally fully bleached softwood Kraft pulp, the fibers being bound together with a cured binder having a Tg in the range of about minus 30 to about 50 degrees C. The mats are pleated prior to assembling the filter in conventional manner. The only fibrous mat in the filters is wet laid fibrous nonwoven mat and the pleated filter media needs no other means of support in the filter frame.

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: 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: 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: Wet laid, nonwoven, fibrous mats suitable for making MERV 6 or higher, filters, and methods of making the nonwoven mats filter media are disclosed. The mats include a blend comprising a major portion of glass fibers, a minor portion of man-made polymer fibers, such as polyester fibers and about 0-30 wt. percent of chemically cross linked bleached Kraft pulp the fibers, and optionally fully bleached softwood Kraft pulp, the fibers being bound together with a cured binder having a Tg in the range of about minus 30 to about 50 degrees C. The mats are pleated prior to assembling the filter in conventional manner. The only fibrous mat in the filters is wet laid fibrous nonwoven mat and the pleated filter media needs no other means of support in the filter frame.

Abstract: Wet laid, nonwoven, fibrous mats suitable for making MERV 6 or higher filters, and methods of making the nonwoven mats are disclosed. The mats include a blend comprising a major portion of glass fibers and a minor portion of man-made polymer fibers, such as polyester fibers, the fibers being bound together with a cured binder having a Tg in the range of about minus 30 to about 50 degrees C. The mats are pleated prior to assembling the filter in conventional manner. The only fibrous mat in the filters is wet laid fibrous nonwoven mat and the pleated filter media needs no other means of support in the filter frame.

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: 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: A fiber glass mat containing a novolac resin having an acid solubility of at least about 35 wt. percent is especially useful for bonding to a light weight fibrous or foam web or board, such as a polymer fiber web. A method of making the mat by wet laying a slurry containing the fiber and the novolac resin particles and then further adding an aqueous solution or slurry containing a crosslinking agent for the novolac resin and a laminate containing the fiber glass mat are disclosed.

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: 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 comprises a blend of a major portion composed of chopped continuous glass fibers having an average fiber diameter ranging from about 8 to 17 &mgr;m and a minor portion composed of fine staple fibers having an average fiber diameter of less than about 5.5 &mgr;m, the minor portion comprising about 1-30 percent of the dry weight of the web. 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: 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 &mgr;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: A wallcovering system, composite wallcovering and method for providing a smooth finished surface to wall substrate are provided. The wallcovering system comprises a composite wallcovering consisting essentially of a decorative wallcovering layer bonded to a base sheet having sufficient stiffness, thickness and compressibility to conceal surface irregularities on a wall surface of a wall substrate. In one aspect of the invention, the composite wallcovering comprises a layer of woven glass fiber adhesively bonded to a nonwoven fiber glass mat. The composite wallcovering can be installed in one step to provide a smooth finished wall surface on the wall substrate.