Fibrous nonwoven mat and method

Abstract

Fibrous nonwoven mats comprising polyetherimid fibers and a binder comprising a resin and an adhesion promoter, and method of making the mat are disclosed. These mats have several uses and are particularly suited as facer mats for fiber reinforced thermoplastic thermoformable materials. When used as a facer, the mat bonds to the thermoformable material and provides a resin rich outer layer and facilitates bonding to a decorative cover.

1 - 20 . (canceled)  
   
   
       21 . A method of making a wet laid nonwoven fibrous mat comprising polyetherimid fibers bound with a resin comprising the steps of: 
 a) dispersing polyamide fibers and in water to form a dilute slurry,    b) flowing said slurry onto a moving a permeable belt to form a wet web of wet nonwoven fibers,    c) treating said web with an aqueous solution or slurry comprising a resin binder mixture,    d) transferring the wet onto an oven belt, and    e) drying said wet layer to form a dry, fibrous, nonwoven mat.    
   
   
       22 . The method of  claim 21  wherein the binder includes a melamine formaldehyde resin.  
   
   
       23 . The method of  claim 21  wherein the binder includes an adhesion promoter.  
   
   
       24 . The method of  claim 22  wherein the binder includes an adhesion promoter.  
   
   
       25 . The method of  claim 21  wherein the binder includes an adhesion promoter selected from the group consisting of primary amines, amino silanes, n-methylpyrillidone, a water-soluble polyester, novolac resin, and phenoxy resin.  
   
   
       26 . The method of  claim 22  wherein the binder includes an adhesion promoter selected from the group consisting of primary amines, amino silanes, n-methylpyrillidone, a water-soluble polyester, novolac resin, and phenoxy resin.  
   
   
       27 . The method of  claim 21  wherein the mat also comprises glass fibers.  
   
   
       28 . The method of  claim 22  wherein the mat also comprises glass fibers.  
   
   
       29 . The method of  claim 23  wherein the mat also comprises glass fibers.  
   
   
       30 . The method of  claim 25  wherein the mat also comprises glass fibers.