Claims
- 1. A coated glass mat comprising:
a glass mat substrate having non-woven glass fibers; a coating which only partially penetrates a thickness of the glass mat substrate but imparts a tensile strength to the coated glass mat which on average is at least 1.33 times greater than the tensile strength of the glass mat substrate without the coating.
- 2. A coated glass mat comprising:
a glass mat substrate having non-woven glass fibers; a coating which only partially penetrates a thickness of the glass mat substrate but imparts a tensile strength to the coated glass mat which on average is at least 1.33 times greater than the tensile strength of the glass mat substrate without the coating, but the coating weight is less than five (5) times the weight of said glass mat substrate.
- 3. The coated glass mat of claim 1 or claim 2, wherein the coated glass mat has a porosity in a range of from 1.3 CFM to 5.0 CFM per square foot.
- 4. The coated glass mat of claim 2, wherein the coating comprises a coating blend which provides the coated glass mat with a porosity sufficient to allow water vapor to escape from a gypsum slurry when heated.
- 5. The coated glass mat of claim 1 or claim 2, wherein the coating is a coating blend comprised of water, latex binder, inorganic pigment, and inorganic binder.
- 6. The coated glass mat of claim 1 or claim 2, wherein said non-woven porous glass mat weighs between about twelve pounds per thousand square feet and about fifty pounds per thousand square feet.
- 7. The coated glass mat of claim 1 or claim 2, wherein the glass mat substrate before coating weighs about fourteen and a half (14.5) pounds per thousand square feet and wherein after coating the coated glass mat has a tensile strength which on average is greater than one hundred twenty pounds per three-inch width.
- 8. The coated glass mat of claim 1 or claim 2, wherein the glass mat substrate before coating weighs about twenty-six and a half (26.5) pounds per thousand square feet and wherein after coating the coated glass mat has a tensile strength which on average is greater than two hundred twenty pounds per three-inch width.
- 9. The coated glass mat of claim 1 or claim 2, wherein penetration of the coating into the glass mat substrate extends a depth of from twenty five percent of a thickness of the coated glass mat to seventy five percent of the thickness of the coated glass mat.
- 10. The coated glass mat of claim 1 or claim 2, wherein the coating uniformly penetrates the glass mat substrate to desired fractional thickness of the coated glass mat.
- 11. The coated glass mat of claim 1 or claim 2, wherein the coating provides a disproportionate increase in tensile strength of the coated glass mat relative to the increase in final weight of the coated glass mat.
- 12. The coated glass mat of claim 1, wherein, on average, the weight of the coated glass mat per unit area is no more than about six times the weight of the glass mat substrate prior to coating.
- 13. A method of forming a coated glass mat comprising applying a coating to a glass mat substrate having non-woven glass fibers in a manner whereby the coating only partially penetrates the glass mat substrate but imparts a tensile strength to the coated glass mat which on average is at least 1.33 times greater than the tensile strength of the glass mat substrate without the coating.
- 14. A method of forming a coated glass mat comprising applying a coating to a glass mat substrate having non-woven glass fibers in a manner whereby the coating only partially penetrates the glass mat substrate but imparts a tensile strength to the coated glass mat which on average is at least 1.33 times greater than the tensile strength of the glass mat substrate without the coating, but the coating weight is less than five (5) times the weight of said glass mat substrate.
- 15. The method of claim 13 or claim 14, wherein the coated glass mat has a porosity in a range of from 1.3 CFM to 5.0 CFM per square foot.
- 16. The method of claim 15, further comprising forming the coating to comprise a coating blend which provides the coated glass mat with a porosity sufficient to allow water vapor to escape from a gypsum slurry when heated.
- 17. The method of claim 13 or claim 14, further comprising forming the coating as a blend comprised of water, latex binder, inorganic pigment, and inorganic binder.
- 18. The method of claim 13 or claim 14, wherein said non-woven porous glass mat weighs between about twelve pounds per thousand square feet and about fifty pounds per thousand square feet.
- 19. The method of claim 13 or claim 14, wherein the glass mat substrate before coating weighs about fourteen and a half (14.5) pounds per thousand square feet and wherein after coating the coated glass mat has a tensile strength which on average is greater than one hundred twenty pounds per three-inch width.
- 20. The method of claim 13 or claim 14, wherein the glass mat substrate before coating weighs about twenty-six and a half (26.5) pounds per thousand square feet and wherein after coating the coated glass mat has a tensile strength which on average is greater than two hundred twenty pounds per three-inch width.
- 21. The method of claim 13 or claim 14, penetrating the coating into the glass mat substrate to a depth from twenty five percent of a thickness of the coated glass mat to seventy five percent of the thickness of the coated glass mat.
- 22. The method of claim 13 or claim 14, further comprising applying the coating in a manner so that the coating uniformly penetrates the glass mat substrate to desired fractional thickness of the coated glass mat.
- 23. The method of claim 13 or claim 14, wherein the coating provides a disproportionate increase in tensile strength of the coated glass mat relative to the increase in final weight of the coated glass mat.
- 24. The method of claim 13, wherein, on average, the weight of the coated glass mat per unit area is no more than about six times the weight of the glass mat substrate prior to coating.
- 23. An apparatus for making a coated glass mat comprising:
an applicator roll which applies a coating to a glass mat substrate traveling thereby; wherein the applicator roll supplies a sufficient amount of the coating to the glass mat substrate whereby the coating only partially penetrates a thickness of the glass mat substrate but imparts a tensile strength to the coated glass mat which on average is at least 1.33 times greater than the tensile strength of the glass mat substrate without the coating.
- 24. The apparatus of claim 23, wherein the glass mat substrate contacts a periphery of the applicator roll around a wrap arc of the applicator roll, and wherein the wrap arc is in a range of from twenty degrees to eighty degrees.
- 25. The apparatus of claim 23, further comprising a scraper blade positioned downstream from the applicator roll in a direction of travel of the coated glass mat, and wherein the coated glass mat travels in a wrap angle over the scraper blade whereby the scraper blade removes excess coating from the coated glass mat, and wherein the wrap angle is less then one hundred seventy five degrees and preferably on the order of one hundred seventy degrees.
- 26. An apparatus for making a coated glass mat comprising:
an applicator roll which applies a coating to a glass mat substrate traveling thereby, the applicator roll being a single kiss-roll applicator; a monolithic scraper blade positioned downstream in a direction of travel of the coated glass mat to remove excess coating; wherein the glass mat substrate is wrapped around the kiss-roll applicator by an arc angle greater than about 20-degrees.
Parent Case Info
[0001] This application claims the priority and benefit of U.S. Provisional Application Serial No. 60/341,277, entitled “METHOD AND COMPOSITION FOR COATING MAT AND ARTICLES PRODUCED THEREWITH”, which is incorporated herein by reference.
Provisional Applications (1)
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Number |
Date |
Country |
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60341277 |
Dec 2001 |
US |