Fiber mat and process of making same

Abstract

A fiber mat of improved hot wet tensile strength and a process of making same is disclosed. The fiber mat consists of fibers; a formaldehyde-free resinous fiber binder coating the fibers; and a binder-modifier which is a functional silane monomer or polymer.

1 . A formaldehyde-free fiber mat for use in a building material, said fiber mat comprising: 
 55% w/w to 99.5% w/w of a plurality of fibers; and    0.05 % w/w to 45% w/w of a formaldehyde-free resinous binder coating said fibers,    and a fiber binder-modifier wherein said fiber binder-modifier is a functional silane monomer or polymer, wherein the wt. ratio of binder:modifier is 1000:1 to 4:1.    
     
     
         2 . The fiber mat of  claim 1  wherein said fiber binder:modifier wt. ratio is about 200:1 to 9:1.  
     
     
         3 . A formaldehyde-free glass fiber mat according to claim wherein said fiber binder-modifier is an aminofunctional silane.  
     
     
         4 . The glass fiber mat of  claim 3  wherein the concentration of said fibers is 55% to about 98% w/w.  
     
     
         5 . The glass fiber mat of  claim 4  having increased hot wet mat tensile strength.  
     
     
         6 . The glass fiber mat of  claim 1  wherein said binder is a styrene-acrylate suspension modified with polycarboxylic acid and a polyol as the cross-linking agent.