Making foam coated mats on-line

Details Making foam coated mats on-line Making foam coated mats on-line

2007-10-23

2007-10-23

Fortuna, José A. (Department: 1731)

Paper making and fiber liberation

Processes and products

With coating after drying

C162S169000, C162S145000, C162S156000, C427S389700, C427S391000, C427S395000

Reexamination Certificate

active

11503614

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.

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