Flexible non-woven mat

Abstract

A non-woven chopped fiber mat is provided that includes a mixture of about 10 to about 100 weight percent glass fibers and about 5 to about 50 weight percent synthetic fibers. The non-woven mat includes a binder composition that includes a binder resin and a silane coupling agent. It has been found that the physical properties (e.g., flexibility, tensile strength) of a non-woven mat may be improved by formulating a soft but strong binder composition for use in forming the mat.

1 - 28 . (canceled) 
     
     
         29 . A non-woven mat comprising:
 about 10 to about 100 weight percent chopped glass fibers;   about 0 to about 90 weight percent synthetic fibers; and   a binder composition comprising a mixture of a thermoset material and a thermoplastic material, and a coupling agent, wherein said non-woven mat increased flexibility and tensile strength.   
     
     
         30 . The non-woven mat according to  claim 29 , wherein said mat comprises about 50 to about 90 weight percent chopped glass fibers and about 10 to 50 weight percent synthetic fibers. 
     
     
         31 . The non-woven mat according to  claim 29 , wherein said chopped glass fibers are blended with said synthetic fibers. 
     
     
         32 . The non-woven mat according to  claim 29 , wherein said synthetic fibers comprise at least one of polypropylene, polyester, and a combination thereof. 
     
     
         33 . The non-woven mat of  claim 29 , wherein said chopped glass fibers have lengths from about 0.25 to about 2.0 inches. 
     
     
         34 . The non-woven mat according to  claim 29 , wherein said synthetic fibers are chopped fibers having lengths from about 0.5 to about 2.0 inches. 
     
     
         35 . The non-woven mat according to  claim 29 , wherein said chopped glass fibers have diameters of about 5 to 20 microns. 
     
     
         36 . The non-woven mat according to  claim 29 , wherein said synthetic fibers have diameters of about 10 to 16 microns. 
     
     
         37 . The non-woven mat according to  claim 29 , wherein said coupling agent is a silane coupling agent. 
     
     
         38 . The non-woven mat according to  claim 29 , wherein said thermoset material comprises at least one of an acrylic material, a urea formaldehyde material, or a combination of the two. 
     
     
         39 . The non-woven mat according to  claim 29 , wherein said thermoplastic material comprises ethylene vinyl acetate. 
     
     
         40 . The non-woven mat according to  claim 29 , wherein said binder resin comprises about 50 to about 100 weight percent thermoplastic material and about 0 to about 50 weight percent thermoset material. 
     
     
         41 . The non-woven mat according to  claim 40 , wherein said binder resin comprises about 70 to about 90 weight percent thermoplastic material and about 0 to about 50 weight percent thermoset material. 
     
     
         42 . The non-woven mat according to  claim 37 , wherein said coupling agent is present in said binder composition in an amount from about 0.05 to about 10 weight percent. 
     
     
         43 . The non-woven mat according to  claim 29 , wherein said binder composition further includes at least one of a dye, an oil, a filler, a colorant, an aqueous dispersion, a UV stabilizer, a lubricant, a wetting agent, a surfactant, and a antistatic agent. 
     
     
         44 . The non-woven mat according to  claim 43 , wherein said aqueous dispersion is an antioxidant dispersion. 
     
     
         45 . The non-woven mat according to  claim 29 , wherein said binder composition is resistant to styrene monomers. 
     
     
         46 . The non-woven mat according to  claim 29 , wherein said mat has an average tensile strength of at least 30 lb in the machine direction and an average tensile strength of at least 20 lb in the cross direction. 
     
     
         47 . The non-woven mat according to  claim 29 , wherein said mat has a Gurley stiffness of about 2000 to about 6000 mgf. 
     
     
         48 . A pultruded composite product comprising:
 at least one roving impregnated with a thermosetting resin; and   a non-woven mat comprising:
 about 10 to about 95 weight percent chopped glass fibers; 
 about 5 to about 90 weight percent synthetic fibers; and 
 a binder composition comprising a mixture of a thermoset material and a thermoplastic material, and a coupling agent, wherein said non-woven mat has increased flexibility and tensile strength. 
   
     
     
         49 . The pultruded composite product of  claim 48 , wherein said non-woven mat comprises about 50 to about 90 weight percent chopped glass fibers and about 10 to 50 weight percent synthetic fibers. 
     
     
         50 . The pultruded composite product according to  claim 48 , wherein coupling agent comprises a silane coupling agent. 
     
     
         51 . The pultruded composite product according to  claim 48 , wherein said thermoset material comprises at least one of an acrylic material, urea formaldehyde material, or a combination of the two. 
     
     
         52 . The pultruded composite product according to  claim 48 , wherein said thermoplastic material comprises ethylene vinyl acetate. 
     
     
         53 . The pultruded composite product according to  claim 48 , wherein the non-woven mat has an average tensile strength of at least 30 lb in the machine direction and at least 20 lb in the cross direction. 
     
     
         54 . The pultruded composite product according to  claim 48 , wherein said non-woven mat has a Gurley stiffness of about 2000 to about 6000 mgf. 
     
     
         55 . A gypsum wall board comprising:
 a gypsum core; and   at least one non-woven mat interfaced with said gypsum core, said non-woven mat comprising:
 about 10 to about 95 weight percent chopped glass fibers; 
 about 5 to about 90 weight percent synthetic fibers; and 
 a binder composition comprising a mixture of a thermoset material and a thermoplastic material, and a silane coupling agent, wherein said non-woven mat has increased flexibility and tensile strength.