Method of making foam coated mat online and coated mat product

Abstract

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.

1 . In a method of making a permeable fibrous mat on a wet process mat machine in which an aqueous slurry containing lass fibers is continuously deposited onto the top surface of a moving permeable forming belt, partially dewatered, followed by applying an aqueous binder to the wet web and again is partially dewatered by passing over a suction box to also reduce the binder content to a desired level, followed by drying the wet web to produce a dry non-woven fibrous mat, the improvement comprising applying a foam or froth onto the wet web after said web has been partially dewatered following the binder application, the foam or froth having a high percentage of air having a blow ratio of at least about 12, the foam forming less than 5 milliliters of liquid in the bottom of an Imhoff cone after 16 hours from the time of filling the cone to a one liter mark and a viscosity of at least about 200 centipoise, and applying said foam at a rate to produce a dry mat having a coating on one face, the mat having a permeability of at least about 150 CFM/sq. ft.  
   
   
       2 . The method of  claim 1  wherein the foam or froth is applied continuously using onto the top surface of the wet web.  
   
   
       3 . The method of  claim 1  wherein a majority of the fibers are glass fibers and said foam is applied at a rate to produce a dry mat having a permeability of at least about 200 CFM/sq. ft.  
   
   
       4 . The method of  claim 1  wherein said foam is applied at a rate to produce a dry mat having a permeability of at least about 350 CFM/sq. ft.  
   
   
       5 . The method of  claim 1  wherein said foam is applied at a rate to produce a dry mat having a permeability of at least about 500 CFM/sq. ft.  
   
   
       6 . The method of  claim 1  wherein the foam has a blow ratio between about 15 and about 30.  
   
   
       7 . The method of  claim 3  wherein the foam has a blow ratio between about 15 and about 30.  
   
   
       8 . The method of  claim 4  wherein the foam has a blow ratio between about 15 and about 30.  
   
   
       9 . The method of  claim 5  wherein the foam has a blow ratio between about 15 and about 30.  
   
   
       10 . The method of  claim 1  wherein the amount of liquid formed in the bottom of the Imhoff cone is less than about 2 milliliters.  
   
   
       11 . The method of  claim 6  wherein the amount of liquid formed in the bottom of the Imhoff cone is less than about 2 milliliters.  
   
   
       12 . The method of  claim 7  wherein the amount of liquid formed in the bottom of the Imhoff cone is less than about 2 milliliters.  
   
   
       13 . The method of  claim 8  wherein the amount of liquid formed in the bottom of the Imhoff cone is less than about 2 milliliters.  
   
   
       14 . The method of  claim 9  wherein the amount of liquid formed in the bottom of the Imhoff cone is less than about 2 milliliters.  
   
   
       15 . The method of  claim 3  wherein the amount of liquid formed in the bottom of an Imhoff cone filled with foam and allowed to age is less than about 2 milliliters.  
   
   
       16 - 26 . (canceled)  
   
   
       27 . In a method of making a permeable fibrous mat on a wet process mat machine in which an aqueous slurry containing glass fibers is continuously deposited onto the top surface of a moving permeable forming belt, partially dewatered, followed by applying an excess of aqueous binder, removing excess aqueous binder to form a wet, bindered web and drying the wet, bindered web to produce a dry non-woven fibrous mat, the improvement comprising applying a foam or froth onto the wet, bindered web after said web has been bindered and again partially dewatered, the foam or froth having a high percentage of air having a blow ratio of at least about 12, the foam forming less than 5 millimeters of liquid in the bottom of an Imhoff cone after 16 hours from filling and a viscosity of at least about 200 centipoise, and applying said foam at a rate to produce a dry mat having a coating on one face, the mat having a permeability of at least about 150 CFM/sq. ft.  
   
   
       28 . The method of  claim 27  wherein at least the majority of the fibers are glass fibers and said foam is applied at a rate to produce a dry mat having a permeability of at least about 200 CFM/sq. ft.  
   
   
       29 . The method of  claim 28  wherein said foam is applied at a rate to produce a dry mat having a permeability of at least about 350 CFM/sq. ft.  
   
   
       30 . The method of  claim 29  wherein said foam is applied at a rate to produce a dry mat having a permeability of at least about 500 CFM/sq. ft.  
   
   
       31 . The method of  claim 27  wherein the foam has a blow ratio of at least about 25.  
   
   
       32 . The method of  claim 28  wherein the foam has a blow ratio of at least about 25.  
   
   
       33 . The method of  claim 29  wherein the foam has a blow ratio of at least about 25.  
   
   
       34 . The method of  claim 30  wherein the foam has a blow ratio of at least about 25.  
   
   
       35 . The method of  claim 27  wherein the amount of liquid formed in the bottom of an Imhoff cone filled with said foam and aged is less than about 2 millimeters.  
   
   
       36 . The method of  claim 31  wherein the amount of liquid formed in the bottom of an Imhoff cone filled with foam and aged is less than about 2 millimeters.  
   
   
       37 . The method of  claim 32  wherein the amount of liquid formed in the bottom of an Imhoff cone filled with foam and aged is less than about 2 millimeters.  
   
   
       38 . The method of  claim 33  wherein the amount of liquid formed in the bottom of an Imhoff cone filled with said foam and aged is less than about 2 millimeters.  
   
   
       39 . The method of  claim 34  wherein the amount of liquid formed in the bottom of an Imhoff cone filled with foam and aged is less than about 2 millimeters.  
   
   
       40 . The method of  claim 28  wherein the amount of liquid formed in the bottom of an Imhoff cone filled with foam and allowed to age is less than about 2 millimeters.  
   
   
       41 - 51 . (canceled)  
   
   
       52 . The method of  claim 1  in which the foam is applied by spraying the aqueous foam through spray nozzles located above the wet web.  
   
   
       53 . The method of  claim 7  in which the foam is applied by spraying the aqueous foam through spray nozzles located above the wet web.  
   
   
       54 . The method of  claim 27  in which the foam is applied by spraying the aqueous foam through spray nozzles located above the wet web.  
   
   
       55 . The method of  claim 28  in which the foam is applied by spraying the aqueous foam through spray nozzles located above the wet web.  
   
   
       56 . The method of  claim 32  in which the foam is applied by spraying the aqueous foam through spray nozzles located above the wet