Johns Manville

Other

Manville Corporation

Richard Emil Kajander

Alan Michael Jaffee

Glenda Beth Bennett

Lance Wang

Paul Russell Swartz

Richard Jon Kindle

Eric J Adamczyk

Paul Russel Swartz

A method of making a nonwoven fibrous mat that retains good strength and recovery after scoring and folding, properties making the mat useful in making collapsible ceiling tile. The mat comprises a majority of glass fibers and a minority of polymer fibers, the fibers being bound together with up to 35 wt. percent of a polyacrylic acid and polyol polymer binder based on the dry weight of the mat. The mat can be cured to 'B stage', thermoformed into the desired shape and then heated further to complete the cure of the binder.

Method of making tough, flexible mats

Coated and uncoated fibrous mats, and laminates containing the mat, having one or more surfactants on the fibers and binder holding the fibers together in only a portion of the thickness of the mat are disclosed. The mat contains a major portion of non-cellulosic fibers and a minor portion of cured resinous binder with the most typical fibers being glass fibers. The surfactant on the surface of the fibers causes a slurry or other liquid applied to the mat in a later process to form a board or laminate like faced gypsum board, a faced foam board, etc. to uniformly penetrate the mat to the desired distance. Also disclosed are methods of applying the surfactant(s) to the hot, coated or uncoated, mat soon after the coated or uncoated mat exits a drying oven used in the process of making, or coating, the mat.

Surfactant coated fibrous nonwoven mats

Methods of making nonwoven mats having good strength after being scored and folded and particularly useful in making lightweight, compressible ceiling panels are disclosed. The mats also have excellent flame resistance. The mats include a blend comprising a major portion of glass fibers and a minor portion of man-made polymer fibers, the fibers being bound together with a cured binder containing a homopolymer or copolymer of polyacrylic acid and a polyol. The binder bonding the mat together can be cured to only a 'B' stage to produce thermoformable mats or more fully cured to produce mats having the properties described above.

Method of making tough, flexible mats and tough, flexible mats

A multilayer fibrous nonwoven mat containing at least one transition zone comprised of a mixture of the slurries used to form the layers on each side of the transition zone, the transition zone having a thickness of at least 1 percent of the thickness of the mat. At least one of the layers contains glass fibers. The multilayer mats are particularly useful as facers on gypsum wall board, insulating foam, a wood material and a broad range of other materials. The multilayer mats are made by a method that involves using a lamella in the forming box on a wet laid mat machine, between slurries, the lamella ending a significant distance prior to a moving forming wire. The transition zone or zones provide superior interlaminar shear strength and other properties compared to multilayer fibrous mats produced on wet laid machines having two or more separate forming boxes.

Method of making multilayer nonwoven fibrous mats

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.

Fiber glass mat, method and laminate

Coated fibrous mats having properties particularly suited for a facer on gypsum wallboard, foam and other substrates and in laminates of various types, and the method of making the coated mat is disclosed. The mat contains a major portion of non-cellulosic fibers and a minor portion of cured resinous binder. The exposed surface coating has a smoothness of no more than about 15 microns and is comprised of one or more of a clay, a filler and a polymeric binder. The method comprises at least partially drying the coated mat while the exposed surface of the coating is in contact with a smooth surface.

Coated mat products, laminates and method

Making mats using glass fibers having a diameter of about 13+/&#x2212;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.

Method of making tough, flexible mats for collapsable ceiling tile

Method of treating a coated fibrous 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 fibrous nonwoven mat particularly suited for hiding the color of a substrate when the mat is bonded to the substrate is made by forming a web of fibers from a wet fibrous slurry, saturating the mat with a resinous binder containing 1-20 weight percent of a paper coating material, removing excess binder from the mat to produce a mat having a resin binder content of 5-25 weight percent and drying the mat. The mat has high hiding power for substrates like board or blanket of fiber glass insulation and other colored materials.

Nonwoven fibrous mats with good hiding properties and laminate

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.

Making foam coated mats on-line

A bond is created between a gypsum matrix formed from an aqueous acidic gypsum slurry comprising a monomer mixture. The monomer mixture is composed of a monomer having acidic functionality and a monomer having hydroxyl or amine functionality. A silane-based sizing composition is coated onto glass fibers causing a cross-linking network of silane and monomer mixture to form during curing of the gypsum board. Hydrophilic water extraction at the gypsum matrix-sizing interface reduces void formation and promotes bonding with the crosslinked monomer mixture and growth of smaller gypsum crystals within larger crystals in microstructurally identifiable regions adjacent to the glass fiber. A bond is created between a gypsum matrix formed from an aqueous acidic gypsum slurry comprising a monomer mixture. The monomer mixture is composed of a monomer having acidic functionality and a monomer having hydroxyl or amine functionality. A silane-based sizing composition is coated onto glass fibers causing a cross-linking network of silane and monomer mixture to form during curing of the gypsum board. Hydrophilic water extraction at the gypsum matrix-sizing interface reduces void formation and promotes bonding with the crosslinked monomer mixture and growth of smaller gypsum crystals within larger crystals in microstructurally identifiable regions adjacent to the glass fiber. Alternatively, the silane based sizing composition has branched chains that diffuse into a wet gypsum mix containing the monomer mixture. During gypsum cure, the diffusion and crosslinking of monomer mixture triggers formation of interpenetrating pseudo polymeric networks within a microstructurally identifiable region adjacent to the glass fiber. Bonds formed between the gypsum matrix and the silane based sizing composition increase the strength, flexure resistance and nail pull out resistance of the gypsum board.

Polymeric bonding of glass fiber reinforcements with silane based coatings in gypsum board

Method of making foam coated mat online

Coated nonwoven fiber mat

The invention includes fibrous nonwoven multiple layer mats having at least two layers with a body portion layer and a surface portion layer having fine fibers and/or particles therein, both layers being bonded together and to each other with a same resin binder. Preferably most or essentially all of the particles and/or fibers in the surface layer are larger than openings between the fibers in the body portion of the mat. The mats produced according to this invention are useful as a facer for all types of boards such as wood boards, wood product boards, insulating boards and hard boards of all types, and also as reinforcement and dimensional stabilizers for making a large number of novel laminate products and for a myriad of other uses. These mats are made an a wet laid nonwoven mat machine with a modification to the binder preparation system, an inventive step in the preparation of the binder and in the selection of ingredients for a binder slurry.

Growing community of inventors

Toledo, OH, United States of America

Richard Emil Kajander