Method of making coated mat online and coated mat products

D - Textiles – Paper – 06 – N

Patent

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Details

D06N 5/00 (2006.01) B32B 13/14 (2006.01) B32B 17/02 (2006.01) D04H 1/58 (2006.01) D21H 21/56 (2006.01) D21H 23/28 (2006.01) E04D 5/00 (2006.01) E04F 13/00 (2006.01) D21H 13/40 (2006.01)

Patent

CA 2396854

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.

L'invention porte sur de nouveaux mats fibreux non tissés dotés de propriétés particulièrement appropriées à un panneau de parement de placoplâtre et d'autres substrats, et dans des stratifiés de divers types, et la méthode de fabrication du mat à revêtement. De préférence, le mat contient une partie principale de fibres de verre et une partie secondaire de liant résineux. Le revêtement est, de préférence, perméable et réduit la poussière des fibres et l'abrasion expérimentée antérieurement avec des fibres de verre relativement grossières et à faible coût dans le mat. Contrairement aux méthodes de revêtement antérieures, le mat fibreux à revêtement est fabriqué en ligne sur une chaîne de production de formage de mat humide au moyen de l'application d'un liant de mousse humide sur une bande fibreuse humide, suivi par le séchage et le traitement en ligne.

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