Johns Manville

Jonhs Manville

Glenda Beth Bennett

Souvik Nandi

Alan Michael Jaffee

Richard Emil Kajander

Thomas Matthews

A glass facer for a constructions board includes a first non-woven layer of coarse fibers and a second non-woven layer of coarse fibers and microfibers. The glass facer also includes a binder that simultaneously binds or adheres the coarse fibers of the first non-woven layer together, the coarse fibers and the microfibers of the second non-woven layer together, and the first non-woven layer to the second non-woven layer. The first non-woven layer has a porosity and air permeability that enables the first non-woven layer to absorb a material of the construction board when the glass facer is positioned atop the construction board during manufacture of the construction board. The second non-woven layer is configured to block the material of the construction board from passing through the glass facer to an exterior surface of the second non-woven layer so that the material is not externally visible.

Multilayer facer

A system for forming a facer includes a hydroformer that receives a first fluid and a second fluid. A first fluid line is configured to deliver the first fluid to a first inlet pipe and a second fluid line configured to deliver the second fluid to a second inlet pipe. The first fluid line includes a first fiber source that stores a first type of fibers and a first thick stock pump that pumps the first type of fibers to the first inlet pipe. The second fluid line includes a second fiber source that stores a second type of fibers and a second thick stock pump that pumps the second fluid to the second inlet pipe. The first fluid and second fluid are simultaneously poured or delivered onto a porous belt or surface to form the facer.

Multilayer facer manufacturing system

Methods of making the burnthrough resistant non-woven mat include forming the mat from glass fibers and at least two binders, a first binder having a vinyl component and a second binder having a strengthening component. The vinyl component may be, for example, ethylene vinyl chloride, and the strengthening component may be, for example, melamine formaldehyde. In one method, the vinyl component is added to the glass fibers by a beater addition process and the strengthening component is sprayed onto the glass fibers. The burnthrough resistant non-woven mat may be used in conjunction with an insulation blanket, and may be especially suited to use in insulating aircraft.

Methods of making a non-woven fire barrier mat

A gypsum board comprises a set gypsum layer having a first face and a second face. An uncoated 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 glass fiber consisting essentially of a major portion composed of chopped continuous glass fibers having an average fiber diameter ranging from about 8 to 25 &#x3bc;m and optionally a minor portion consisting essentially of at least one of small diameter glass fibers having a fiber diameter of at most about 13 &#x3bc;m and microfibers having an average fiber diameter ranging from about 0.05 to about 6.5 &#x3bc;m. The board is exceedingly durable and has a high resistance to water absorption, rendering it particularly useful for exterior insulation systems.

Non-woven glass fiber mat faced gypsum board and process of manufacture

Dispersion of a fire retardant agent in a binder used to form a fire retardant fiberglass mat allows for easy and uniform incorporation of the fire retardant agent into the fire retardant fiberglass mat. The fire retardant fiberglass mat is bonded to a fiberglass insulation batt, providing fire retardant composite useful as duct board or equipment liner.

Fire retardant fiberglass mat

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.

Method of making coated mat online

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.

Growing community of inventors

Toledo, OH, United States of America

Glenda Beth Bennett