Method of making improved fiber glass mat, laminates made with the mat, and method of making laminates

Abstract

A method of making a fiber glass mat especially useful for bonding to wood contains glass fibers and a “B” staged resin is disclosed. A substantial portion of the resin binder can be a furfuryl alcohol formaldehyde, phenol formaldehyde, melamine formaldehyde, or any other resin that can be “B” staged. Also, a method of making wood and wood product laminates using this new mat without any other adhesives, and the resultant laminates are disclosed.

I claim:  
     
         1 . A method of making a fiber glass mat for bonding to wood or to a wood product wherein an aqueous mixture comprising a binder is applied to a wet, nonwoven mat of unbonded, crossing glass fibers followed by drying said mat and curing said resin to form a bonded glass fiber mat, the improvement comprising drying and curing the mat only partially to “B” stage the resin binder.  
     
     
         2 . The method of    claim 1    wherein the major portion of the mat is glass fibers.  
     
     
         3 . The method of    claim 1    wherein cellulosic fibers or fibers of a cellulose derivative are mixed with the glass fibers to make said mat.  
     
     
         4 . The method of    claim 1    wherein a substantial portion of the resin binder is selected from a group consisting of furfuryl alcohol formaldehyde based resin, phenol formaldehyde resin and melamine formaldehyde resin.  
     
     
         5 . The method as described in    claim 2    wherein a substantial portion of the resin binder is selected from a group consisting of furfuryl alcohol formaldehyde based resin, phenol formaldehyde resin and melamine formaldehyde resin.  
     
     
         6 . The method as described in    claim 3    wherein a substantial portion of the resin binder is selected from a group consisting of furfuryl alcohol formaldehyde based resin, phenol formaldehyde resin and melamine formaldehyde resin.  
     
     
         7 . The method as described in    claim 4    wherein a substantial portion of the resin binder is a furfuryl alcohol formaldehyde based resin.  
     
     
         8 . The method as described in    claim 5    wherein a substantial portion of the resin binder is a furfuryl alcohol formaldehyde based resin.  
     
     
         9 . The method as described in    claim 6    wherein a substantial portion of the resin binder is a furfuryl alcohol formaldehyde based resin.  
     
     
         10 . The method as described in    claim 1    wherein a substantial portion of the resin binder is a furfuryl alcohol formaldehyde based resin.  
     
     
         11 . A method of making a wood laminate or wood product laminate by pressing a wood or wood product against a fiber glass nonwoven mat under while being heated to complete the cure of the binder in the mat, said mat comprising glass fibers bonded together with about 15-75 weight percent of a resin binder wherein the resin binder is derived from an aqueous resin selected from the group consisting of furfuryl alcohol formaldehyde based resin, phenol formaldehyde resin and melamine formaldehyde resin and is only partially cured to a “B” stage condition and wherein said mat also contains cellulosic fibers or fibers of a cellulose derivative.  
     
     
         12 . The method as described in    claim 11    wherein the major portion of the mat is glass fibers and up to 75 weight percent of the mat is fibers.  
     
     
         13 . The method as described in    claim 12    wherein the mat also contains a cure catalyst in the resin binder.  
     
     
         14 . The method as described in    claim 11    wherein said glass fibers are less than 3 inches long and are in the form of a nonwoven mat.  
     
     
         15 . The method as described in    claim 13    wherein said glass fibers are less than 3 inches long and are in the form of a nonwoven mat.  
     
     
         16 . A laminate of wood or a wood product bonded to a glass fiber nonwoven mat comprising glass fibers bonded together with about 15-75 weight percent of a resin binder wherein the resin binder is derived from an aqueous resin selected from the group consisting of furfuryl alcohol formaldehyde based resin, phenol formaldehyde resin and melamine formaldehyde resin and is only partially cured to a “B” stage condition and wherein said mat also contains cellulosic fibers or fibers of a cellulose derivative.  
     
     
         17 . The method as described in    claim 16    wherein the major portion of the mat is glass fibers and up to 75 weight percent of the mat is fibers.  
     
     
         18 . The method as described in    claim 17    wherein the mat also contains a cure catalyst in the resin binder.  
     
     
         19 . The method as described in    claim 16    wherein said glass fibers are less than 3 inches long and are in the form of a nonwoven mat.  
     
     
         20 . The method as described in    claim 18    wherein said glass fibers are less than 3 inches long and are in the form of a nonwoven mat.