Abstract: The present invention provides a formulation for a fibrous non-woven facing material, wherein the formulation comprises a binder, a filler, and an extender. The extender has an median particle size, d50, which is equal to or less than 3.5 ?m, and a non-spherical morphology. The filler has an median particle size, d50, which is equal to or less than 3.0 ?m and wherein the filler has a d10 equal to or less than 1.0 ?m and a d90 equal to or less than 6.0 ?m. The formulation comprises less than 13 wt % titanium dioxide on a dry solids basis. Also provided is a fibrous non-woven facing material comprising the formulation, a process for preparing the fibrous non-woven facing material and a fibrous non-woven facing material obtained by said process.

Abstract: The present invention provides a formulation for a fibrous non-woven facing material, wherein the formulation comprises a binder, a filler, and an extender. The extender has an median particle size, d50, which is equal to or less than 3.5 ?m, and a non-spherical morphology. The filler has an median particle size, d50, which is equal to or less than 3.0 ?m and wherein the filler has a d10 equal to or less than 1.0 ?m and a d90 equal to or less than 6.0 ?m. The formulation comprises less than 13 wt % titanium dioxide on a dry solids basis. Also provided is a fibrous non-woven facing material comprising the formulation, a process for preparing the fibrous non-woven facing material and a fibrous non-woven facing material obtained by said process.

Abstract: A non-woven fibrous mat is provided that includes a mixture of thermoset resins and a thermoplastic resin. It has been found that the physical properties (e.g., flexibility, tensile strength) of a non-woven mat may be improved by formulating a binder composition comprising variable ratios of the thermoset material and the thermoplastic material. In this way, a bonded nonwoven mat may be achieved having a desirable combination of strength and flexibility, while maintain good heat and water resistance.

Abstract: A cross-linked nonwoven fibrous mat is disclosed comprising a core layer including a fibrous precursor mat bound with a formaldehyde-free core binder composition and a cross-linker disposed on at least one surface of the core layer, said cross-linker comprising one or more of isocyanate, polyol, and melamine functional groups. The cross-linked nonwoven mat has a hot-wet retention of at least 25%.

Abstract: A cross-linked nonwoven fibrous mat is disclosed comprising a core layer including a fibrous precursor mat bound with a formaldehyde-free core binder composition and a cross-linker disposed on at least one surface of the core layer, said cross-linker comprising one or more of isocyanate, polyol, and melamine functional groups. The cross-linked nonwoven mat has a hot-wet retention of at least 25%.

Abstract: A non-woven fibrous mat is provided that includes a mixture of a thermoset resin and a thermoplastic resin. It has been found that the physical properties (e.g., flexibility, tensile strength) of a non-woven mat may be improved by formulating a binder composition comprising variable ratios of the thermoset material and the thermoplastic material. In this way, a bonded nonwoven mat may be achieved having a desirable combination of strength and flexibility, while maintaining good heat and water resistance.

Abstract: The present invention provides a formulation for a fibrous non-woven facing material, wherein the formulation comprises a binder, a filler, and an extender. The extender has an median particle size, d50, which is equal to or less than 3.5 ?m, and a non-spherical morphology. The filler has an median particle size, d50, which is equal to or less than 3.0 ?m and wherein the filler has a d10 equal to or less than 1.0 ?m and a d90 equal to or less than 6.0 ?m. The formulation comprises less than 13 wt % titanium dioxide on a dry solids basis. Also provided is a fibrous non-woven facing material comprising the formulation, a process for preparing the fibrous non-woven facing material and a fibrous non-woven facing material obtained by said process.

Abstract: A UV-cured coated facer includes a non-woven mat having a first side and a second side and an intermediate coating disposed on the first side of the non-woven mat. The intermediate coating includes a coating binder and a filler. The UV-cured coated facer also includes a UV-curable coating composition disposed on the intermediate coating, wherein the UV-curable coating composition is essentially free of a filler.

Abstract: Methods that apply decorative particles in-line in the manufacturing process to form a decorative structured mat or veil that is ready for direct commercial application. The decorative particles or decorative paint patterns should be of a size and/or color to be visible at a distance of five meters from the decorative mat or veil. In preferred embodiments, the particle size ranges from about 100 to about 500 microns in size. A formulation for coating a glass fiber mat with decorative particles is also provided.

Abstract: A precursor of a fiber reinforced foam structure includes a base veil having between about 50 and about 75 weight percent reinforcement fibers and between about 50 and about 25 weight percent veil binder. The base veil has a weight per unit area of between about 35 and about 400 g/m2. Further the base veil is impregnated with an expandable binder in an amount of between about 20 to about 200 g/m2.

Abstract: An impregnated fibrous veil comprises a nonwoven fibrous veil including a prebinder and reinforcing fibers. The fibers are selected from a group consisting of glass fibers, ceramic fibers and mixtures thereof. The nonwoven fibrous veil has at least one face impregnated with a surface finish formulation. The surface finish formulation includes about 50 to about 95 weight percent filler, about 5 to about 50 weight percent binder and about 0 to about 10 percent optical brightener.

Abstract: Methods that apply decorative particles in-line in the manufacturing process to form a decorative structured mat or veil that is ready for direct commercial application. The decorative particles or decorative paint patterns should be of a size and/or color to be visible at a distance of five meters from the decorative mat or veil. In preferred embodiments, the particle size ranges from about 100 to about 500 microns in size. A formulation for coating a glass fiber mat with decorative particles is also provided. To make the decorative structured mat or veil more flexible, a portion of the glass filament fibers may be replaced by a plurality of polymeric fibers. Also, a plurality of flame retardant fibers may be added to the conformable decorative structured mat or veil to improve flame retardancy.

Abstract: Methods that apply decorative particles in-line in the manufacturing process to form a decorative structured mat or veil that is ready for direct commercial application. The decorative particles or decorative paint patterns should be of a size and/or color to be visible at a distance of five meters from the decorative mat or veil. In preferred embodiments, the particle size ranges from about 100 to about 500 microns in size. A formulation for coating a glass fiber mat with decorative particles is also provided.

Abstract: A method for making a nonwoven reinforcing may for vinyl floor coverings is described. A base mat is formed from a mixture of glass fibers and polymeric binder fibers and/or powder, follows by treatment with a second water-based polymeric binder composition. The mat has been found to be highly satisfactory as a substrate for compressible vinyl floor covering.

Abstract: A method for making a nonwoven reinforcing may for vinyl floor coverings is described. A base mat is formed from a mixture of glass fibers and polymeric binder fibers and/or powder, follows by treatment with a second water-based polymeric binder composition. The mat has been found to be highly satisfactory as a substrate for compressible vinyl floor covering.