Permeable glass mat and method of preparation

Abstract

Provided is a coated nonwoven mat prepared by the process of passing a nonwoven mat over the surface of a binder or coating slurry to touch the bottom side of the mat sufficiently to fully wet the glass mat. The wetted nonwoven mat is then immersed in a slurry of the binder or coating material to fully saturate the mat with the slurry material. The process of the present invention allows one to control the porosity of the saturated fibrous nonwoven mat at high consistency with reduced scrap rate. The saturated mat will have improved tensile strength.

1 . A permeable, coated, fibrous, nonwoven mat made by the process of passing the nonwoven mat over the surface of a binder or coating slurry to touch the bottom side of the mat sufficiently to fully wet the glass mat, and immersing the mat in a slurry to fully saturate the mat with the slurry material. 
     
     
         2 . The nonwoven mat of  claim 1 , wherein the nonwoven mat has been dried with infrared heaters, or other heating device such as microwave, electromagnetic radiation. 
     
     
         3 . The nonwoven mat of  claim 2 , wherein the drying of the nonwoven mat is completed in an oven. 
     
     
         4 . The nonwoven mat of  claim 1 , wherein the mat is immersed in the slurry at least two times. 
     
     
         5 . The nonwoven mat of  claim 1 , wherein a blade or rotating roll set is used to remove excessive slurry to a desired level. 
     
     
         6 - 13 . (canceled) 
     
     
         14 . A laminate comprised of a first layer and a second layer, with the second layer comprising the nonwoven mat of  claim 1 . 
     
     
         15 . The laminate of  claim 14 , wherein the first layer is gypsum board. 
     
     
         16 . The laminate of  claim 14 , wherein the first layer is a polyiso board.