Aqueous composition for coating non-woven fibrofelt

Abstract

An aqueous composition for coating a nonwoven fibrofelt, the aqueous composition comprising: an aqueous hydrophobic binder; two thickening agents; an inorganic filler; a dispersant; and water. The two thickeners are independently selected from the group consisting of acrylic polymers wherein one thickener has a weight average molecular weight of from about 50,000 g / mol to about 1,000,000 g / mol as determined by gel permeation chromatography and the other thickener has a weight average molecular weight of from about 1,000,000 g / mol to about 3,800,000 g / mol as determined by gel permeation chromatography. The aqueous hydrophobic binder is a copolymer of i) monomeric units selected from vinyl versatate, isomers of vinyl versatate, or mixtures thereof; and ii) at least one monomeric unit selected from the group consisting of (meth) acrylic acid and (meth) acrylic acid esters. Also described herein are coated non-woven fiber mats, methods for making coated non-woven fiber mats, and building panels comprising the coated non-woven fiber mats.

Description

[0001] Cross-references to related applications

[0002] This application claims priority and benefit to European Patent Application No. 23198074.9, filed on 18 September 2023, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] The present invention relates to an aqueous composition for coating nonwoven fiber mat, a coated nonwoven fiber mat, a method for manufacturing the coated nonwoven fiber mat, and a building panel comprising the coated nonwoven fiber mat. Background Technology

[0004] Fiber mats, such as fiberglass mats, have been used as cladding in the manufacture of building panels, such as gypsum board and polyisocyanurate board. Traditionally, cladding materials include nonwoven fiber mats, including nonwoven fiberglass mats. Compared to conventional panels clad with polyester, paper, or other cellulose cladding materials, nonwoven fiberglass cladding can be used to produce panels with specific properties, such as increased dimensional stability in the presence of moisture, increased biocompatibility, increased air permeability, and better physical and mechanical properties, such as better strength and durability.

[0005] Nonwoven fiber mats typically comprise randomly entangled glass fibers bonded together by a cured thermosetting agent or a dried thermoplastic polymer binder. Processes for forming such mats are generally well-known, including, for example, well-known wet web forming and dry web forming methods. In an exemplary wet web forming process for forming nonwoven glass fiber mats, chopped glass fibers are provided via a storage container to a conveying device (such as a conveyor) to a mixing tank that may contain white water (e.g., various surfactants, viscosity modifiers, defoamers, and / or other chemical reagents), accompanied by agitation to disperse the fibers and form a chopped glass fiber slurry. The glass fiber slurry may be transferred to a headbox, where it is deposited onto a conveying device (such as a moving screen or porous conveyor), and most of the water in the slurry is removed to form an entangled fiber web (mat). Water can be removed from the web using conventional vacuum or air suction systems.

[0006] The precursor binder can be mixed into white water. Alternatively, the precursor binder can be applied to the entangled fiber web as described above using a suitable binder applicator (such as a sprayer or curtain coater).

[0007] Once the adhesive is applied to the felt, the adhesive-coated felt is passed through at least one drying oven to remove any residual water and dry and / or cure the adhesive composition. The shaped nonwoven fiber felt emerging from the oven is an aggregate of randomly oriented, dispersed individual glass fibers.

[0008] The nonwoven fiber felt can then be coated or impregnated with a coating composition and dried and / or cured to form a cladding material to impart various properties to the cladding and downstream building panel panels. For building panel panels, and generally for gypsum board, it is important to have a cladding that allows the gypsum slurry to dry to form the gypsum board while preventing the gypsum slurry from seeping through the fiber felt.

[0009] To avoid being bound by theory, fiber felt used for gypsum board needs to have two properties:

[0010] • Breathability—The fiber felt must be both sufficiently breathable (i.e., open) to allow the gypsum slurry to dry properly via the evaporation of water vapor through the fiber felt, and sufficiently impermeable (i.e., sealed) to prevent the gypsum slurry from seeping out; and

[0011] • Hydrophobicity—The fiber mat must exhibit an appropriate degree of hydrophobicity to prevent undesirable seepage of water-based gypsum slurry through the fiber mat, and to provide resistance to damp environments, especially when the gypsum board is used for exterior purposes.

[0012] For cladding used in building panels, it is also expected that it will adhere firmly to the plaster core once dry.

[0013] Several techniques are known for coating nonwoven fiber mats, such as fountain, curtain, doctor blade, rod, roller-to-roll, or reverse roller coating techniques.

[0014] Typically, the coating composition used is a complex composition containing more than ten different components to provide suitable processability in the manufacture of fiber felt and to enable the coated felt to achieve the target performance (breathability, degree of hydrophobicity, and adhesion) in the application.

[0015] In fact, obtaining a simple composition that satisfies the processability requirements of roller-lined doctor blade coating technology while allowing the fiber mat to have the desired performance characteristics (i.e., good adhesion to gypsum, air permeability and hydrophobicity) is particularly challenging.

[0016] The purpose of this invention is to overcome or mitigate at least some of the problems in the prior art.

[0017] definition

[0018] The attachment point of repeating units, parts, or substituents is indicated by a "-". For example, -COOH is attached via a carbon atom.

[0019] The terms “about” or “approximately” mean the acceptable error of a particular value as determined by one of ordinary skill in the art, depending in part on how the value was measured or determined. The terms “about” or “approximately” may mean within 1, 2, 3, or 4 standard deviations. The terms “about” or “approximately” may mean within 30%, 25%, 20%, 15%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, or 0.5% of a given value or range.

[0020] Unless otherwise specified, the terms “a,” “an,” “the,” and “at least one” are used interchangeably. Furthermore, as used in the specification and appended claims of this application, the singular forms “a,” “an,” and “the” include their plural forms, unless the surrounding context contradicts them.

[0021] "Alkyl" refers to a straight-chain, branched, or cyclic saturated hydrocarbon group. An alkyl group may have 5 to 20 carbon atoms, for example 7 to 17 carbon atoms, such as 10 to 15 carbon atoms. An alkyl group may be unsubstituted. Alternatively, an alkyl group may be substituted. Unless otherwise stated, an alkyl group may be attached at any suitable carbon atom, and if substituted, may be substituted at any suitable atom.

[0022] "Aryl" refers to an aromatic carbocyclic group or an aromatic heterocyclic group. When an aryl group is an aromatic carbocyclic group, it can have a monocyclic or multiple fused rings. An aryl group can have 5 to 20 carbon atoms, for example 6 to 20 carbon atoms, such as 6 to 12 carbon atoms. An aryl group can be unsubstituted. Alternatively, an aryl group can be substituted. Unless otherwise stated, an aryl group can be attached to any suitable carbon atom, and if substituted, it can be substituted at any suitable atom. Examples of aryl groups include, but are not limited to, phenyl, tolyl (ortho-, meta-, or para-), naphthyl, anthracene, etc.

[0023] When the aryl group is an aromatic heterocyclic ring group, one or more (e.g., 1, 2, 3 or more) carbon atoms in the aromatic carbon ring group are independently substituted by heteroatoms, provided that aromaticity is maintained. An aromatic heterocyclic ring group may also be called a heteroaryl group. A heteroaryl group may have a monocyclic or multiple fused rings. The heteroatom, or each heteroatom, may be independently selected from the group consisting of nitrogen, oxygen, phosphorus, and sulfur. The heteroatom, or each heteroatom, may be selected from nitrogen. A heteroaryl group may have 4 to 20 carbon atoms, for example 5 to 20 carbon atoms, such as 5 to 15 carbon atoms. A heteroaryl group may be unsubstituted. Alternatively, a heteroaryl group may be substituted. Unless otherwise stated, a heteroaryl group may be attached at any suitable atom, and if substituted, may be substituted at any suitable atom. Examples of heteroaryl groups include, but are not limited to, thienyl, furanyl, pyrroleyl, imidazolyl, pyrazolyl, thiazolyl, isothiazolyl, oxazolyl, isoxazolyl, triazolyl, thiadiazolyl, thienyl, oxadiazolyl, pyridyl, pyrimidinyl, benzoxazolyl, benzothiazolyl, benzimidazolyl, indolyl, quinolinyl, etc.

[0024] The term "composed of" is closed and excludes additional, unlisted elements or method steps in the claimed invention.

[0025] The term "consistently composed of" is semi-closed, falling between "composed of" and "comprising". "Constitutes essentially composed of" does not exclude additional, unlisted elements or method steps that do not substantially affect the essential features of the claimed invention.

[0026] The term "comprising" is inclusive or open-ended and does not exclude additional, unlisted elements or method steps in the claimed invention. This term is synonymous with "including but not limited to". The term "comprising" covers three alternatives: (i) "comprising", (ii) "consisting of", and (iii) "consisting substantially of".

[0027] The terms “felt,” “thin felt,” and “covering” are used interchangeably in this document and refer to bonded fiber webs.

[0028] Viscosity is a function of shear rate. A decrease in viscosity of a composition (e.g., a paste) with increasing shear rate is called "shear thinning," while an increase in viscosity of a composition (e.g., a paste) is called "shear thickening."

[0029] The term “substantially free” means that the selected composition contains less than the stated ingredient or component in a functional amount, typically less than about 0.1% by weight of the total composition, such as less than about 0.05% by weight, for example less than about 0.03% by weight.

[0030] "Substituted" refers to a group in which one or more (e.g., 1, 2, 3, 4, or 5) hydrogen atoms are each independently replaced by substituents that may be the same or different. Substituents can be any group that does not adversely affect the aqueous compositions of the present invention, the coated nonwoven felts or precursor felts of the present invention. Examples of substituents include, but are not limited to, -R. a -OR a -NR a R b -CN, -COOR a and -CONR a R b Preferred -R a R a and R b The group is independently selected from the group consisting of H, alkyl and aryl groups (such as phenyl, tolyl (ortho-, meta- or para-), naphthyl, anthracene, methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl, pentyl, cyclopentyl, hexyl, cyclohexyl, etc.). Detailed Implementation

[0031] Aqueous Composition

[0032] In one aspect, the present invention provides an aqueous composition for coating nonwoven fiber mats, the composition comprising:

[0033] • Water-based hydrophobic adhesives;

[0034] • Two thickeners independently selected from acrylic polymers,

[0035] One of the thickeners has a weight-average molecular weight of approximately 500,000 g / mol to approximately 1,000,000 g / mol, as determined by gel permeation chromatography (GPC), and

[0036] Another thickener has a weight-average molecular weight of approximately 100,000 g / mol to approximately 380,000 g / mol, as determined by gel permeation chromatography; and

[0037] •Inorganic fillers;

[0038] • Dispersants; and

[0039] •water;

[0040] The aqueous hydrophobic adhesive is a copolymer of the following:

[0041] i) a monomeric unit selected from ethylene tert-carbonate, its isomers, or mixtures thereof; and

[0042] ii) at least one monomer unit selected from (meth)acrylic acid or (meth)acrylate.

[0043] Although the various components in the aqueous composition may be expressed as ranges, the total weight % of the aqueous composition is 100 by weight.

[0044] Aqueous hydrophobic adhesives are copolymers of the following:

[0045] i) a monomeric unit selected from ethylene tert-carbonate, its isomers, or mixtures thereof; and

[0046] ii) at least one monomer unit selected from (meth)acrylic acid or (meth)acrylate.

[0047] Vinyl tert-carbonate and its isomers are hydrophobic. Without being bound by theory, it is believed that long-chain alkyl groups contribute to the hydrophobicity of the copolymer.

[0048] The monomeric unit of tertiary vinyl carbonate (also known as neodecanoic acid vinyl ester) has the following structure:

[0049]

[0050] Ethylene tert-carbonate contains branched alkyl chains, namely -(CH2)5- t Bu. Isomers of tert-vinyl carbonate include those with -C9H 19 Other vinyl ester monomers with alkyl groups. Isomers of tertiary vinyl carbonate include those with a straight-chain -C9H group. 19 Vinyl ester monomers with alkyl groups, i.e., H₂C=C(H)-OC(O)-(CH₂)₈-CH₃. Isomers of tertiary vinyl carbonate include those with branched -C₉H groups. 19 Vinyl ester monomers with alkyl groups, such as H2C=C(H)-OC(O)-C(CH3)(CH3)-(CH2)5-CH3, H2C=C(H)-OC(O)-CH2-C(CH3)(CH3)-(CH2)4-CH3, H2C=C(H)-OC(O)-(CH2)2-C(CH3)(CH3)-(CH2)3-CH3, H2C=C(H)-OC(O)-(CH2)3-C(CH3)(CH3)-(CH2)2-CH3 and H2C=C(H)-OC(O)-(CH2)4-C(CH3)(CH3)-CH2-CH3.

[0051] The other monomer unit is selected from the group consisting of (meth)acrylic acid and (meth)acrylate. This monomer unit can be selected from the group consisting of acrylic acid, methacrylic acid, methyl methacrylate, acrylate, methacrylate, and combinations thereof.

[0052] Aqueous hydrophobic binders can be stabilized with surfactants, such as anionic surfactants. Suitable emulsion stabilizers are known in the art and are described below.

[0053] The weight percentage of the hydrophobic adhesive can range from about 3% to about 40% by weight of the total weight of the aqueous composition. The weight percentage of the hydrophobic adhesive can range from about 5% to about 30% by weight of the total weight of the aqueous composition. The weight percentage of the hydrophobic adhesive can be ≥ about 6% by weight of the total weight of the aqueous composition. The weight percentage of the hydrophobic adhesive can be ≥ about 7% by weight of the total weight of the aqueous composition. The weight percentage of the hydrophobic adhesive can be ≥ about 8% by weight of the total weight of the aqueous composition. The weight percentage of the hydrophobic adhesive can be ≥ about 9% by weight of the total weight of the aqueous composition. The weight percentage of the hydrophobic adhesive can be ≥ about 10% by weight of the total weight of the aqueous composition. The weight percentage of the hydrophobic adhesive can be ≥ about 10.5% by weight of the total weight of the aqueous composition. The weight percentage of the hydrophobic adhesive can be ≥ about 11% by weight of the total weight of the aqueous composition. The weight percentage of the hydrophobic adhesive can be ≥ about 11.5% by weight of the total weight of the aqueous composition. The weight percentage of the hydrophobic adhesive can be ≥ about 12% by weight of the total weight of the aqueous composition.

[0054] The weight percentage of the hydrophobic adhesive can be ≤ about 30% by weight of the total weight of the aqueous composition. The weight percentage of the hydrophobic adhesive can be ≤ about 25% by weight of the total weight of the aqueous composition. The weight percentage of the hydrophobic adhesive can be ≤ about 20% by weight of the total weight of the aqueous composition. The weight percentage of the hydrophobic adhesive can be ≤ about 17% by weight of the total weight of the aqueous composition. The weight percentage of the hydrophobic adhesive can be ≤ about 16% by weight of the total weight of the aqueous composition. The weight percentage of the hydrophobic adhesive can be ≤ about 15% by weight of the total weight of the aqueous composition. The weight percentage of the hydrophobic adhesive can be ≤ about 14% by weight of the total weight of the aqueous composition. The weight percentage of the hydrophobic adhesive can be ≤ about 13% by weight of the total weight of the aqueous composition.

[0055] The weight percentage of the hydrophobic binder may be in the range of about 12% to about 13% of the total weight of the aqueous composition, such as about 12.5% ​​by weight.

[0056] The hydrophobic binder can be an aqueous dispersion, meaning the copolymer can be dispersed in a medium (water). The solids content of the binder in water can range from about 20% to about 70% by weight of the total weight of the aqueous composition. The solids content of the binder in water can range from about 30% to about 60% by weight of the total weight of the aqueous composition. The solids content of the binder in water can be ≥ about 35% by weight of the total weight of the aqueous composition. The solids content of the binder in water can be ≥ about 39% by weight of the total weight of the aqueous composition. The solids content of the binder in water can be ≥ about 40% by weight of the total weight of the aqueous composition. The solids content of the binder in water can be ≥ about 41% by weight of the total weight of the aqueous composition. The solids content of the binder in water can be ≥ about 42% by weight of the total weight of the aqueous composition. The solids content of the binder in water can be ≥ about 43% by weight of the total weight of the aqueous composition.

[0057] The solid content of the binder in water may be ≤ about 60% by weight of the total weight of the aqueous composition. The solid content of the binder in water may be ≤ about 55% by weight of the total weight of the aqueous composition. The solid content of the binder in water may be ≤ about 50% by weight of the total weight of the aqueous composition. The solid content of the binder in water may be ≤ about 49% by weight of the total weight of the aqueous composition. The solid content of the binder in water may be ≤ about 48% by weight of the total weight of the aqueous composition. The solid content of the binder in water may be ≤ about 47% by weight of the total weight of the aqueous composition. The solid content of the binder in water may be ≤ about 46% by weight of the total weight of the aqueous composition. The solid content of the binder in water may be ≤ about 45% by weight of the total weight of the aqueous composition.

[0058] The solid content of the binder in water can be approximately 44% by weight of the total weight of the aqueous composition.

[0059] The aqueous composition contains two thickeners independently selected from acrylic polymers.

[0060] One of the thickeners has a weight-average molecular weight (M) of approximately 500,000 g / mol to approximately 1,000,000 g / mol, as determined by gel permeation chromatography. W ),and

[0061] Another thickener has a weight-average molecular weight (M) of approximately 100,000 g / mol to approximately 380,000 g / mol, as determined by gel permeation chromatography. W ).

[0062] Since thickeners are polymers, each thickener can be a mixture of polymers having a weight-average molecular weight within the range described herein.

[0063] The embodiments provide a method for determining M by GPC. W The appropriate method.

[0064] One thickener has a higher M than the other thickener W Range. Thickeners may have an M of about 600,000 g / mol to about 900,000 g / mol, such as about 700,000 g / mol to about 850,000 g / mol. W .

[0065] One thickener has a smaller M than another thickener W Range. Thickeners may have an M such as about 150,000 g / mol to about 300,000 g / mol, or such as about 200,000 g / mol to about 250,000 g / mol. W .

[0066] The thickener is independently selected from acrylic polymers. The thickener may be selected from acrylic polymers of the same type. The thickener may be selected from acrylic polymers of different types. The thickener may be independently selected from anionic acrylic polymers or hydrophobically modified anionic acrylic polymers. Anionic acrylic polymers and hydrophobically modified anionic acrylic polymers are known in the art.

[0067] M has a higher concentration than the other thickener W The range of thickeners can be anionic acrylic polymers, and have a lower M value than another thickener. W Thickeners in this range can be hydrophobically modified anionic acrylic polymers.

[0068] One thickener may have medium to high shear, for example, having a lower M than another thickener. W Thickeners in the range of medium to high shear rates. An example of a medium-to-high shear thickener is TAFIGEL, sold by Münzing Chemie. ® AP 17.

[0069] One thickener may have low shear, for example, having an M greater than that of another thickener. W A range of thickeners. An example of a low-shear thickener is TAFIGEL, sold by Münzing Chemie. ® AP 11.

[0070] Thickeners identified as “medium-high shear” or “low shear” thickeners are known in the art.

[0071] A customized combination of thickeners enables the aqueous composition to exhibit high viscosity at low shear at room temperature (e.g., 25°C) and thixotropy at high shear, meaning that the viscosity of the aqueous composition decreases when it comes into contact with a doctor blade in a roller-lined doctor blade coating process. Not wanting to be bound by theory, although both thickeners show viscosity reduction at both low shear forces (e.g., 5 rpm) and high shear forces (e.g., 100 rpm), they exhibit a smaller M... W Thickeners typically have a higher M value than those with a higher M value. W Thickeners have higher viscosity. Furthermore, those with lower M... W Thickeners also typically exhibit higher M values ​​than those with higher M values. W The thickener exhibits a greater viscosity difference at low shear forces (e.g., 5 rpm) and high shear forces (e.g., 100 rpm).

[0072] Any suitable amount of both thickeners can be used in an aqueous composition, provided that the aqueous composition has a high viscosity at low shear and is thixotropic at high shear, i.e., its viscosity decreases when it comes into contact with a doctor blade in a roller-blade coating technique.

[0073] The aqueous composition may be alkaline. The pH may be any suitable alkaline pH, provided that it does not adversely affect the composition, any component of the composition, the precursor felt, or the coated nonwoven fabric felt. The pH of the aqueous composition may be ≥ about 8 and ≤ about 12.

[0074] The aqueous composition may contain a pH adjuster. By weight of the total aqueous composition, the aqueous composition may contain about 0.01% to about 0.5%, for example about 0.05% to about 0.4%, such as about 0.1% to about 0.3% (for example about 0.2%) of a pH adjuster. The pH adjuster may be selected from one or more (e.g., 1, 2, 3, 4, 5 or more) inorganic bases. Alternatively or otherwise, the pH adjuster may be selected from one or more (e.g., 1, 2, 3, 4, 5 or more) organic bases. When it is necessary to make the pH of the aqueous composition alkaline or higher, suitable examples of pH adjusters include, but are not limited to, calcium hydroxide, sodium hydroxide, potassium hydroxide, 30% ammonia, aminomethylpropanol (e.g., 2-amino-2-methyl-1-propanol), 2-dimethylaminoethanol, diethanolamine, 3-dimethylamino-1-propanol, or N-methylethanolamine. When the pH of an aqueous composition is too high and it is necessary to reduce its alkalinity, suitable examples of pH adjusters include acids such as citric acid, acetic acid, oxalic acid, and lactic acid.

[0075] When the acrylic thickener has an M value of approximately 500,000 g / mol to approximately 1,000,000 g / mol as determined by GPC... W At room temperature (e.g., 25°C) and a pH of approximately 8.2, a 2% aqueous solution of the thickener may have the following viscosity:

[0076] • At 5 rpm, approximately 150 mPa·s to approximately 250 mPa·s, such as approximately 192 mPa·s; and

[0077] • At 100 rpm, it is approximately 25 mPa·s to approximately 150 mPa·s, such as approximately 77 mPa·s.

[0078] When the acrylic thickener has an M value of approximately 500,000 g / mol to approximately 1,000,000 g / mol as determined by GPC... W At room temperature (e.g., 25°C) and a pH of approximately 10, a 4% aqueous solution of the thickener may have the following viscosity:

[0079] • At 5 rpm, approximately 500 mPa·s to approximately 600 mPa·s, such as approximately 534 mPa·s; and

[0080] • At 100 rpm, approximately 200 mPa·s to approximately 300 mPa·s, such as approximately 246 mPa·s.

[0081] When the acrylic thickener has an M value of approximately 100,000 g / mol to approximately 380,000 g / mol as determined by GPC... W At room temperature (e.g., 25°C) and a pH of approximately 8.5, a 2% aqueous solution of the thickener may have the following viscosity:

[0082] • At 5 rpm, approximately 1700 mPa·s to approximately 1800 mPa·s, such as approximately 1730 mPa·s; and

[0083] • At 100 rpm, approximately 250 mPa·s to approximately 350 mPa·s, such as approximately 295 mPa·s.

[0084] When the acrylic thickener has an M value of approximately 100,000 g / mol to approximately 380,000 g / mol as determined by GPC... W At room temperature (e.g., 25°C) and a pH of approximately 10, a 2% aqueous solution of the thickener may have the following viscosity:

[0085] • At 5 rpm, approximately 1000 mPa·s to approximately 1300 mPa·s, such as approximately 1290 mPa·s; and

[0086] • Approximately 200 mPa·s to approximately 300 mPa·s at 100 rpm, such as approximately 258 mPa·s.

[0087] Having an M of approximately 500,000 g / mol to approximately 1,000,000 g / mol as determined by GPC W The weight percentage of the thickener can be independently selected from the following range.

[0088] Having M values ​​of approximately 100,000 g / mol to approximately 380,000 g / mol as determined by GPC W The weight percentage of the thickener can be independently selected from the following range.

[0089] The weight percentage of each thickener may range from about 0.05 wt% to about 1 wt% of the total weight of the aqueous composition. The weight percentage of each thickener may range from about 0.1 wt% to about 0.8 wt% of the total weight of the aqueous composition. The weight percentage of each thickener may be ≥ about 0.15 wt% of the total weight of the aqueous composition. The weight percentage of each thickener may be ≥ about 0.2 wt% of the total weight of the aqueous composition. The weight percentage of each thickener may be ≥ about 0.25 wt% of the total weight of the aqueous composition.

[0090] The weight percentage of each thickener may be ≤ about 0.8% by weight of the total weight of the aqueous composition. The weight percentage of each thickener may be ≤ about 0.75% by weight of the total weight of the aqueous composition. The weight percentage of each thickener may be ≤ about 0.7% by weight of the total weight of the aqueous composition. The weight percentage of each thickener may be ≤ about 0.65% by weight of the total weight of the aqueous composition. The weight percentage of each thickener may be ≤ about 0.6% by weight of the total weight of the aqueous composition. The weight percentage of each thickener may be ≤ about 0.5% by weight of the total weight of the aqueous composition.

[0091] The weight percentage of each thickener may be in the range of about 0.25% to about 0.6% of the total weight of the aqueous composition.

[0092] With a large M w The weight percentage of the thickener may be approximately 0.52% of the total weight of the aqueous composition.

[0093] With a smaller M W The weight percentage of the thickener may be about 0.3% of the total weight of the aqueous composition.

[0094] The aqueous composition contains inorganic filler. Filler may also be referred to as mineral pigment. Any suitable filler may be used. When coated nonwoven felt is used in gypsum board, it is generally desirable that the filler / mineral pigment be white. Examples of fillers suitable for preparing coated felt include, but are not limited to, calcium carbonate, magnesium carbonate, talc, aluminum trihydrate, vermiculite, antimony oxide, titanium dioxide, aluminum trihydrate (Al₂O₃), clay, or any combination of two or more of these substances. An example of a suitable filler is calcium carbonate.

[0095] When the filler is calcium carbonate, calcium carbonate can act as a buffer, and the pH of the aqueous composition can be stabilized.

[0096] The amount of filler in coated nonwoven fiber felt can be described as a weight percentage of the filler based on the total weight of the aqueous composition. Not wishing to be bound by theory, fillers (e.g., calcium carbonate) can impart opacity and a white appearance to the bonded fiber nonwoven felt.

[0097] The aqueous composition may contain filler in the range of about 50% to about 95% by weight of the total weight of the aqueous composition. The aqueous composition may contain filler in an amount of ≥50% by weight of the total weight of the coating composition. The aqueous composition may contain filler in an amount of ≥55% by weight of the total weight of the aqueous composition. The aqueous composition may contain filler in an amount of ≥60% by weight of the total weight of the aqueous composition. The aqueous composition may contain filler in an amount of ≥61% by weight of the total weight of the aqueous composition. The aqueous composition may contain filler in an amount of ≥62% by weight of the total weight of the aqueous composition.

[0098] The aqueous composition may contain filler in an amount of ≤95% by weight of the total weight of the aqueous composition. The aqueous composition may contain filler in an amount of ≤90% by weight of the total weight of the aqueous composition. The aqueous composition may contain filler in an amount of ≤85% by weight of the total weight of the aqueous composition. The aqueous composition may contain filler in an amount of ≤80% by weight of the total weight of the aqueous composition. The aqueous composition may contain filler in an amount of ≤75% by weight of the total weight of the aqueous composition. The aqueous composition may contain filler in an amount of ≤70% by weight of the total weight of the aqueous composition. The aqueous composition may contain filler in an amount of ≤69% by weight of the total weight of the aqueous composition. The aqueous composition may contain filler in an amount of ≤68% by weight of the total weight of the aqueous composition. The aqueous composition may contain filler in an amount of ≤67% by weight of the total weight of the aqueous composition. The aqueous composition may contain filler in an amount of ≤66% by weight of the total weight of the aqueous composition. The aqueous composition may contain filler in an amount of ≤65% by weight of the total weight of the aqueous composition. The aqueous composition may contain filler in an amount of ≤64% by weight of the total weight of the aqueous composition.

[0099] The aqueous composition may contain filler in the range of about 62% to about 64% by weight of the total weight of the aqueous composition (such as about 63% by weight).

[0100] The aqueous composition contains a dispersant. Suitable examples of dispersants include, but are not limited to, polyphosphates, polycarboxylates, poly(meth)acrylates, or citrates, such as ammonium polyphosphate, sodium polyphosphate, ammonium polycarboxylate, sodium polycarboxylate, ammonium poly(meth)acrylate, sodium poly(meth)acrylate, ammonium citrate, or sodium citrate. The dispersant may be sodium polyphosphate.

[0101] The weight percentage of the dispersant can range from about 0.05 wt% to about 1 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant can range from about 0.1 wt% to about 0.8 wt% of the total weight of the aqueous composition.

[0102] The weight percentage of the dispersant can be ≥ about 0.05 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant can be ≥ about 0.06 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant can be ≥ about 0.07 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant can be ≥ about 0.08 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant can be ≥ about 0.09 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant can be ≥ about 0.1 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant can be ≥ about 0.11 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant can be ≥ about 0.12 wt% of the total weight of the aqueous composition.

[0103] The weight percentage of the dispersant may be ≤ about 0.8 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant may be ≤ about 0.7 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant may be ≤ about 0.6 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant may be ≤ about 0.5 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant may be ≤ about 0.45 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant may be ≤ about 0.4 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant may be ≤ about 0.35 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant may be ≤ about 0.3 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant may be ≤ about 0.25 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant may be ≤ about 0.2 wt% of the total weight of the aqueous composition. The weight percentage of the dispersant may be ≤ about 0.15 wt% of the total weight of the aqueous composition.

[0104] The weight percentage of the dispersant may be in the range of about 0.12 wt% to about 0.15 wt% of the total weight of the aqueous composition, such as about 0.13 wt%.

[0105] The composition of the present invention is aqueous, i.e. contains water. There is no particular limitation on the amount of water in the composition, provided that the viscosity of the composition is not so high as to inhibit the deposition of the aqueous composition on the precursor felt, or so low as to make the composition too flowable to adequately coat the precursor felt.

[0106] The aqueous composition may contain water in the range of about 10% to about 50% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≥10% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≥15% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≥16% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≥17% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≥18% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≥19% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≥20% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≥21% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≥22% by weight of the total weight of the aqueous composition.

[0107] The aqueous composition may contain water in an amount of ≤50% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≤45% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≤35% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≤30% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≤29% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≤28% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≤27% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≤26% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≤25% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≤24% by weight of the total weight of the aqueous composition. The aqueous composition may contain water in an amount of ≤23% by weight of the total weight of the aqueous composition.

[0108] The aqueous composition may contain water in the range of about 22% to about 23% by weight of the total weight of the aqueous composition (such as about 22.9% by weight).

[0109] If necessary, when calculating the amount of water to be used, the amount of water present in the water-based hydrophobic binder or pH adjuster (if a pH adjuster is used and if the pH adjuster contains water) may be taken into account.

[0110] The aqueous composition is thixotropic. A suitable method for determining the thixotropy of the aqueous composition is the thixotropy test provided in the examples.

[0111] The aqueous composition may also contain additives selected from the group consisting of biocides, defoamers, pigments, preservatives, emulsion stabilizers, wetting and leveling agents, crosslinking agents, and combinations thereof.

[0112] The aqueous composition may optionally contain a biocide. Scaling of nonwoven felts and coverings occurs primarily through the buildup of charged particles, biological growth, and fungal growth. Biological or fungal infestation is more typically a problem in pools, showers, and other hot, humid environments, but can also occur in any surface covering or drywall application. Examples of suitable biocides include, but are not limited to, diiodomethyl-p-tolyl sulfone, glutaraldehyde, isothiazolin, isothiazolin derivatives, zinc oxide, zinc omepridine, sodium omepridine, and silver, such as sodium omepridine. To prevent discoloration or unwanted microbial or fungal infestation, biocides, such as antimicrobial agents and / or antifungal agents, may be present in the coated nonwoven felt. The aqueous composition may contain about 0.00001% to about 0.15% of a biocide by weight of the aqueous hydrophobic binder, filler, dispersant, thickener, water, biocide, and one or more additional additives (if present). The aqueous composition may contain about 0.0001% to about 0.015%, such as about 0.0005% to about 0.001% of a biocide, based on the total weight of the aqueous hydrophobic binder, filler, dispersant, thickener, water, biocide, and one or more other additives (if present).

[0113] The aqueous composition may optionally contain pigments. For the purposes of this invention, the pigments may be either inorganic or organic in nature. Suitable pigments are known to those skilled in the art. They are typically provided in pulverized form, for example, as primary particles or as pigment agglomerates. Examples of suitable pigments include, but are not limited to, iron oxide, copper carbonate, copper hydroxide, calcium copper silicate, cobalt blue aluminate, ultramarine blue, azo pigments, titanium dioxide, zinc sulfide, and any desired mixtures thereof. The aqueous composition may contain about 0.01% to about 3%, for example, about 0.1% to about 2%, such as about 0.5% to about 1.5% of pigment by weight of the total aqueous composition. Suitable examples of pigments include, but are not limited to, white pigments and blue pigments.

[0114] Aqueous compositions may consist essentially of the following:

[0115] • Water-based hydrophobic adhesives;

[0116] • Two thickeners independently selected from acrylic polymers,

[0117] One of the thickeners has a weight-average molecular weight of approximately 500,000 g / mol to approximately 1,000,000 g / mol, as determined by gel permeation chromatography.

[0118] Another thickener has a weight-average molecular weight of about 100,000 g / mol to about 380,000 g / mol, as determined by gel permeation chromatography.

[0119] •Inorganic fillers;

[0120] • Dispersant;

[0121] • Biocides;

[0122] • Water; and

[0123] • Optional pigments;

[0124] The aqueous hydrophobic adhesive is a copolymer of the following:

[0125] i) a monomeric unit selected from ethylene tert-carbonate, its isomers, or mixtures thereof; and

[0126] ii) at least one monomer unit selected from (meth)acrylic acid or (meth)acrylate.

[0127] Aqueous compositions may consist of the following:

[0128] • Water-based hydrophobic adhesives;

[0129] • Two thickeners independently selected from acrylic polymers,

[0130] One of the thickeners has a weight-average molecular weight of approximately 500,000 g / mol to approximately 1,000,000 g / mol, as determined by gel permeation chromatography.

[0131] Another thickener has a weight-average molecular weight of about 100,000 g / mol to about 380,000 g / mol, as determined by gel permeation chromatography.

[0132] •Inorganic fillers;

[0133] • Dispersant;

[0134] • Biocides;

[0135] • Water; and

[0136] • Optional pigments;

[0137] The aqueous hydrophobic adhesive is a copolymer of the following:

[0138] i) a monomeric unit selected from ethylene tert-carbonate, its isomers, or mixtures thereof; and

[0139] ii) at least one monomer unit selected from (meth)acrylic acid or (meth)acrylate.

[0140] The aqueous composition may optionally contain a defoamer. A defoamer is also called an antifoaming agent. The aqueous composition may contain about 0.001% to about 1%, for example about 0.2% to about 0.7%, such as about 0.4% to about 0.6%, or such as about 0.5%, of the total weight of the aqueous solution. Suitable examples of defoamers include, but are not limited to, siloxanes, mineral oils and polyoxyethylenes, modified fatty and alkoxylated compounds, silica, emulsifiers, or combinations thereof. The defoamer (or antifoaming agent) may be a blend of modified fatty and alkoxylated compounds, silica, and emulsifiers, stabilized with a nonionic surfactant.

[0141] Alternatively, the aqueous composition does not contain an antifoaming agent.

[0142] The aqueous composition may contain an emulsion stabilizer. Based on the total weight of the aqueous composition, the aqueous composition may contain about 0.01% to about 0.5%, for example about 0.05% to about 0.4%, such as about 0.1% to about 0.3% of an emulsion stabilizer. Suitable examples of emulsion stabilizers include, but are not limited to, bentonite, nonionic octylphenol ethoxylate surfactants, tall oil resins, and natural resin extracts.

[0143] Alternatively, the aqueous composition does not contain an emulsion stabilizer.

[0144] The aqueous composition may contain wetting and leveling agents. By weight of the total aqueous composition, the aqueous composition may contain about 0.01% to about 0.5%, for example about 0.05% to about 0.4%, such as about 0.1% to about 0.3%, of a wetting and leveling agent. Suitable examples of wetting and leveling agents include, but are not limited to, sulfosuccinates, polyether-modified siloxanes, urea-modified polyurethanes, and modified urea ammonium salts of acrylate copolymers.

[0145] Alternatively, the aqueous composition does not contain wetting and leveling agents.

[0146] The aqueous composition may contain a crosslinking agent. Based on the total weight of the aqueous composition, the aqueous composition may contain about 0.01% to about 0.5%, for example about 0.05% to about 0.4%, such as about 0.1% to about 0.3%, of a crosslinking agent. Suitable examples of crosslinking agents include, but are not limited to, zinc oxide, zinc metal ions, stabilized zirconium carbonate containing anionic hydroxylated zirconium polymers, and epoxy-functionalized silanes.

[0147] Alternatively, the aqueous composition does not contain a crosslinking agent.

[0148] Coated nonwoven fiber mat

[0149] In one aspect, the present invention relates to a coated nonwoven fiber felt comprising:

[0150] (a) a precursor felt, comprising:

[0151] • Including nonwoven fiber webs made of glass fiber, and

[0152] • First adhesive;

[0153] and

[0154] (b) A hydrophobic coating applied to the precursor felt, wherein the hydrophobic coating is formed from an aqueous composition as described herein.

[0155] The precursor felt is coated with an aqueous composition as described herein. Once dry, the coating is hydrophobic.

[0156] The coated nonwoven fiber felt is asymmetrical. "Asymmetrical" means that the aqueous composition of the present invention does not completely impregnate the precursor felt. Instead, the aqueous composition is coated only on one side of the precursor felt or located on one side of the precursor felt. In this respect, the aqueous composition will be detectable on the coated side of the precursor felt, but not on the other side of the felt (uncoated).

[0157] The coated nonwoven fiber mat includes a precursor mat. The precursor mat includes (a) a nonwoven fiber web comprising glass fibers, and (b) a first binder, or a combination thereof.

[0158] Nonwoven fiber webs refer to glass fibers that are randomly oriented.

[0159] Glass fibers can be formed by conventional methods known to those skilled in the art. In this regard, glass fibers can be formed by a continuous manufacturing process in which molten glass is passed through holes in a stencil, the resulting molten glass flow solidifies into filaments, and the filaments are combined together to form fibers, “rovings,” “raw yarns,” etc.

[0160] After the glass fibers are drawn from the stencil, an aqueous sizing composition (also called a sizing agent) may optionally be applied to the fibers. This sizing composition is not limited and can be any sizing composition known to those skilled in the art. Typically, the sizing composition contains a lubricant to protect the fibers from abrasion damage. The sizing composition can be applied by conventional methods, such as by application rollers or by spraying the sizing agent directly onto the fibers. The sizing agent protects the glass fibers from breakage during subsequent processing, helps slow interfilament abrasion, ensures the integrity of the glass fiber filaments, and promotes the interconnection of the glass filaments forming the filaments, etc.

[0161] After glass fibers are treated with a sizing composition, they can be chopped for subsequent processing into wet-laid nonwoven mats as described below. The chopped fibers can have varying lengths within the nonwoven mat.

[0162] Glass fibers may have the average fiber diameter and the average fiber length described below.

[0163] Glass fibers can have an average fiber diameter ranging from ≥ about 5 μm to ≤ about 20 μm. Glass fibers can have an average fiber diameter ranging from ≥ about 8 μm to ≤ about 17 μm. Glass fibers can have an average fiber diameter ranging from ≥ about 10 μm to ≤ about 15 μm.

[0164] Glass fibers can have an average fiber diameter of ≥8 μm. Glass fibers can have an average fiber diameter of ≥8.5 μm. Glass fibers can have an average fiber diameter of ≥9 μm. Glass fibers can have an average fiber diameter of ≥9.5 μm. Glass fibers can have an average fiber diameter of ≥10 μm. Glass fibers can have an average fiber diameter of ≥10.5 μm. Glass fibers can have an average fiber diameter of ≥11 μm. Glass fibers can have an average fiber diameter of ≥11.5 μm. Glass fibers can have an average fiber diameter of ≥12 μm. Glass fibers can have an average fiber diameter of ≥12.5 μm.

[0165] Glass fibers can have an average fiber diameter of ≤17 μm. Glass fibers can have an average fiber diameter of ≤16.5 μm. Glass fibers can have an average fiber diameter of ≤16 μm. Glass fibers can have an average fiber diameter of ≤15.5 μm. Glass fibers can have an average fiber diameter of ≤15 μm. Glass fibers can have an average fiber diameter of ≤14.5 μm. Glass fibers can have an average fiber diameter of ≤14 μm. Glass fibers can have an average fiber diameter of ≤13.5 μm.

[0166] Glass fibers can have an average fiber diameter of about 13 μm.

[0167] Glass fibers can have an average fiber length ranging from approximately 8 mm to approximately 30 mm. Glass fibers can have an average fiber length ranging from approximately 10 mm to approximately 28 mm. Glass fibers can have an average fiber length ranging from approximately 12 mm to approximately 26 mm. Glass fibers can have an average fiber length ranging from approximately 14 mm to approximately 24 mm.

[0168] Glass fibers may have an average fiber length of ≥14.5 mm. Glass fibers may have an average fiber length of ≥15 mm. Glass fibers may have an average fiber length of ≥15.5 mm. Glass fibers may have an average fiber length of ≥16 mm. Glass fibers may have an average fiber length of ≥16.5 mm. Glass fibers may have an average fiber length of ≥17 mm. Glass fibers may have an average fiber length of ≥17.5 mm. Glass fibers may have an average fiber length of ≥18 mm. Glass fibers may have an average fiber length of ≥18.5 mm.

[0169] Glass fibers can have an average fiber length of ≤23.5 mm. Glass fibers can have an average fiber length of ≤23 mm. Glass fibers can have an average fiber length of ≤22.5 mm. Glass fibers can have an average fiber length of ≤22 mm. Glass fibers can have an average fiber length of ≤21.5 mm. Glass fibers can have an average fiber length of ≤21 mm. Glass fibers can have an average fiber length of ≤20.5 mm. Glass fibers can have an average fiber length of ≤20 mm. Glass fibers can have an average fiber length of ≤19.5 mm.

[0170] Glass fibers can have an average fiber length of about 19 mm.

[0171] The glass fiber may contain SiO2 ranging from about 50 wt% to about 65 wt% of the total weight of the glass composition. The glass fiber may contain SiO2 ranging from about 51 wt% to about 62 wt% of the total weight of the glass composition. The glass fiber may contain SiO2 ranging from about 52 wt% to about 62 wt% of the total weight of the glass composition (such as about 52 wt% to about 56 wt% or about 55 wt% to about 60.4 wt% of the total weight of the glass composition). The glass fiber may contain SiO2 ranging from about 54 wt% to about 62 wt% of the total weight of the glass composition. The glass fiber may contain about 58 wt% of the total weight of the glass composition. The glass fiber may contain about 59 wt% of the total weight of the glass composition. The glass fiber may contain about 60 wt% of the total weight of the glass composition, such as about 60.1 wt% of SiO2.

[0172] The glass fiber may contain Al2O3 ranging from about 7 wt% to about 25 wt% of the total weight of the glass composition. The glass fiber may contain Al2O3 ranging from about 7 wt% to about 20 wt% of the total weight of the glass composition. The glass fiber may contain Al2O3 ranging from about 19 wt% to about 25 wt% of the total weight of the glass composition. The glass fiber may contain Al2O3 ranging from about 9 wt% to about 15 wt% of the total weight of the glass composition. The glass fiber may contain Al2O3 ranging from about 12 wt% to about 16 wt% of the total weight of the glass composition (e.g., from about 12 wt% to about 15 wt% of the total weight of the glass composition). The glass fiber may contain Al2O3 ranging from about 17 wt% to about 20 wt% of the total weight of the glass composition. The glass fiber may contain about 11.5 wt% of Al2O3, such as about 11.6 wt% of the total weight of the glass composition. The glass fiber may contain about 12 wt% of Al2O3, such as about 12.1 wt% of the total weight of the glass composition. The glass fiber may contain about 13% by weight of the total weight of the glass composition, such as about 13.2% by weight of Al2O3.

[0173] Glass fibers may contain B2O3, meaning they are boron-containing glass fibers. Glass fibers may contain B2O3 ranging from about 1% to about 12% by weight of the total weight of the glass composition. Glass fibers may contain B2O3 ranging from about 4% to about 6% by weight of the total weight of the glass composition. Glass fibers may contain B2O3 ranging from about 5% to about 10% by weight of the total weight of the glass composition. Glass fibers may contain B2O3 ranging from about 7% to about 12% by weight of the total weight of the glass composition. Not wishing to be bound by theory, boron-containing glass fibers generally have a lower softening point than boron-free glass fibers. The processes used to prepare these fibers typically use less energy than those for boron-free fibers (because the glass melt generally has a lower softening point). The lower softening point of boron-containing glass fibers can be advantageous in the application of the fibers.

[0174] Glass fibers may be substantially free of B2O3, meaning they can be essentially boron-free fibers. Glass fibers may contain less than 0.2% by weight of B2O3 from the total weight of the glass composition. Glass fibers may not contain B2O3, meaning they can be boron-free fibers. Not wishing to be bound by theory, boron-free or substantially boron-free glass fibers are more environmentally friendly than boron-containing glass fibers because the melt used to manufacture the fibers does not release boron into the environment during processing. The fibers themselves typically have a higher softening point than boron-containing fibers, which can be advantageous in the application of the fibers.

[0175] The glass fiber may contain CaO ranging from about 7 wt% to about 30 wt% of the total weight of the glass composition. The glass fiber may contain CaO ranging from about 7 wt% to about 12 wt% of the total weight of the glass composition. The glass fiber may contain CaO ranging from about 12 wt% to about 30 wt% of the total weight of the glass composition. The glass fiber may contain CaO ranging from about 16 wt% to about 25 wt% of the total weight of the glass composition (such as from about 17 wt% to about 25 wt% of the total weight of the glass composition). The glass fiber may contain CaO ranging from about 21 wt% to about 23 wt% of the total weight of the glass composition. The glass fiber may contain CaO ranging from about 24 wt% to about 30 wt% of the total weight of the glass composition. The glass fiber may contain about 21.7 wt% of the total weight of the glass composition. The glass fiber may contain about 22 wt% of the total weight of the glass composition. The glass fiber may contain about 22.1 wt% of the total weight of the glass composition. The glass fiber may contain about 22.6% by weight of CaO, which is a percentage of the total weight of the glass composition.

[0176] The glass fiber may contain MgO ranging from about 0.1 wt% to about 15 wt% of the total weight of the glass composition. The glass fiber may contain MgO ranging from about 0.1 wt% to about 8 wt% of the total weight of the glass composition (e.g., from about 0.1 wt% to about 4 wt% of the total weight of the glass composition). The glass fiber may contain MgO ranging from about 8 wt% to about 15 wt% of the total weight of the glass composition. The glass fiber may contain MgO ranging from about 0.1 wt% to about 5 wt% of the total weight of the glass composition. The glass fiber may contain MgO ranging from about 0.4 wt% to about 4 wt% of the total weight of the glass composition. The glass fiber may contain about 2 wt% of the total weight of the glass composition. The glass fiber may contain about 3.1 wt% of the total weight of the glass composition. The glass fiber may contain about 3.4 wt% of the total weight of the glass composition.

[0177] Glass fibers may contain virtually no MgO, meaning they can be essentially magnesium-free fibers.

[0178] The glass fiber may contain ZnO in the range of about 0.1 wt% to about 4 wt% of the total weight of the glass composition. The glass fiber may contain ZnO in the range of about 0.5 wt% to about 1 wt% (such as about 1 wt%) of the total weight of the glass composition.

[0179] The glass fiber may contain ZnO ranging from about 2% to about 5% by weight of the total weight of the glass composition. The glass fiber may contain ZnO ranging from about 1% to about 4% by weight of the total weight of the glass composition (e.g., from about 1.1% to about 3% by weight). The glass fiber may contain about 2.9% by weight of ZnO of the total weight of the glass composition.

[0180] Glass fibers may be substantially free of ZnO, meaning they can be essentially zinc-free fibers.

[0181] The glass fiber may contain BaO in the range of about 0.1 wt% to about 3 wt% of the total weight of the glass composition. The glass fiber may contain BaO in the range of about 0.5 wt% to about 1 wt% (such as about 1 wt%) of the total weight of the glass composition. The glass fiber may contain BaO in the range of about 1 wt% to about 3 wt% (such as about 1.1 wt% to about 3 wt%) of the total weight of the glass composition.

[0182] Glass fibers may be substantially free of BaO, meaning they can be essentially barium-free fibers. Glass fiber groups may not contain BaO, meaning they can be barium-free fibers.

[0183] The glass fiber may contain Li₂O in the range of about 0.1 wt% to about 1 wt% of the total weight of the glass composition. The glass fiber may contain Li₂O in the range of about 0.1 wt% to about 0.4 wt% of the total weight of the glass composition. The glass fiber may contain Li₂O in the range of about 0.5 wt% to about 1 wt% of the total weight of the glass composition.

[0184] Glass fibers may be substantially free of Li₂O, meaning they can be substantially lithium-free fibers. Glass fibers may contain less than 0.2% by weight of Li₂O from the total weight of the glass composition. Glass fibers may be free of Li₂O, meaning they can be lithium-free fibers.

[0185] The glass fiber may contain Na₂O and K₂O in the range of about 0.1 wt% to about 5 wt% of the total weight of the glass composition. The glass fiber may contain Na₂O and K₂O in the range of about 0.1 wt% to about 4 wt% of the total weight of the glass composition (e.g., about 0.5 wt% to about 4 wt% of the total weight of the glass composition). The glass fiber may contain a total amount of Na₂O and K₂O in the range of about 0.1 wt% to about 2 wt% of the total weight of the glass composition (e.g., about 0.1 wt% to about 1 wt% of the total weight of the glass composition). The glass fiber may contain a total amount of Na₂O and K₂O in the range of about 0.1 wt% to about 0.3 wt% of the total weight of the glass composition. The glass fiber may contain about 0.1 wt% to about 0.2 wt% of the total weight of the glass composition. The glass fiber may contain about 0.9 wt% of the total weight of the glass composition. The glass fiber may contain about 0.8% by weight of Na₂O and K₂O of the total weight percentage of the glass composition. The glass fiber may contain about 1.2% by weight of Na₂O and K₂O of the total weight percentage of the glass composition.

[0186] Glass fibers may be substantially free of Na₂O or K₂O, meaning they can be essentially sodium-free and potassium-free fibers.

[0187] The glass fiber may contain TiO2 in the range of about 0.1 wt% to about 5 wt% of the total weight of the glass composition. The glass fiber may contain TiO2 in the range of about 0.1 wt% to about 4 wt% of the total weight of the glass composition. The glass fiber may contain TiO2 in the range of about 0.1 wt% to about 0.2 wt% of the total weight of the glass composition (such as about 0.1 wt% to about 1.5 wt%). The glass fiber may contain TiO2 in the range of about 0.2 wt% to about 0.5 wt% of the total weight of the glass composition. The glass fiber may contain about 0.5 wt% of the total weight of the glass composition. The glass fiber may contain about 1.5 wt% of the total weight of the glass composition. The glass fiber may contain about 2.5 wt% of the total weight of the glass composition.

[0188] Glass fibers may contain virtually no TiO2, meaning they can be essentially titanium-free fibers.

[0189] The glass fiber may contain ZrO2 in the range of about 0.1 wt% to about 1 wt% of the total weight of the glass composition. The glass fiber may contain ZrO2 in the range of about 0.1 wt% to about 0.4 wt% of the total weight of the glass composition. The glass fiber may contain ZrO2 in the range of about 0.5 wt% to about 1 wt% of the total weight of the glass composition.

[0190] Glass fibers may be substantially free of ZrO2, meaning they can be essentially zirconium-free fibers.

[0191] The glass fiber may contain Fe2O3 in the range of about 0.1 wt% to about 2 wt% of the total weight of the glass composition. The glass fiber may contain Fe2O3 in the range of about 0.1 wt% to about 0.8 wt% of the total weight of the glass composition. The glass fiber may contain Fe2O3 in the range of about 0.2 wt% to about 0.4 wt% of the total weight of the glass composition. The glass fiber may contain about 0.1 wt% of Fe2O3 in the total weight of the glass composition. The glass fiber may contain about 0.2 wt% of Fe2O3 in the total weight of the glass composition.

[0192] Glass fibers can be substantially free of Fe2O3, meaning they can be essentially iron-free fibers.

[0193] The glass fiber may contain F2 ranging from about 0.1 wt% to about 2 wt% of the total weight of the glass composition. The glass fiber may contain F2 ranging from about 0.1 wt% to about 1 wt% of the total weight of the glass composition. The glass fiber may contain F2 ranging from about 0.2 wt% to about 0.7 wt% of the total weight of the glass composition. The glass fiber may contain about 0.1 wt% of F2 of the total weight of the glass composition.

[0194] Glass fibers may be substantially free of F2, meaning they can be essentially fluorine-free fibers. Glass fibers may contain less than 0.2% by weight of F2 from the total weight of the glass composition. Glass fibers may be free of F2, meaning they can be fluorine-free fibers. Without being bound by theory, fluorine-free or substantially fluorine-free fibers are more environmentally friendly than fluorine-containing fibers.

[0195] Glass fiber may comprise a composition comprising:

[0196]

[0197] Although the various components in the glass may be expressed as ranges, the total weight % of the composition is totaled as 100% by weight.

[0198] Glass fibers may comprise boron-containing E-glass, boron-free E-glass, ECR-glass, H-glass, or mixtures thereof. Glass fibers may comprise boron-containing E-glass fibers. Glass fibers may comprise boron-free E-glass fibers. Glass fibers may comprise ECR-glass fibers. Glass fibers may comprise a mixture of boron-containing E-glass and boron-free E-glass fibers. Glass fibers may comprise a mixture of boron-containing E-glass and ECR-glass fibers. Glass fibers may comprise a mixture of boron-free E-glass and ECR-glass fibers. Glass fibers may comprise a mixture of boron-containing E-glass, boron-free E-glass fibers, and ECR-glass fibers. Glass fibers may comprise H-glass.

[0199] The boron-containing E-glass composition may include:

[0200]

[0201] Although the various components in E-glass can be expressed as ranges, the total weight % of the composition is totaled as 100% by weight.

[0202] The composition of boron-free E-glass may include:

[0203]

[0204] Although the various components in E-glass can be expressed as ranges, the total weight % of the composition is 100% by weight. In this case, boron-free E-glass does not contain F2.

[0205] Alternatively or otherwise, the boron-free E-glass composition may include:

[0206]

[0207] Although the various components in E-glass can be expressed as ranges, the total weight % of the composition is totaled at 100% by weight. In this case, the boron-free E-glass contains F2.

[0208] The composition of ECR-glass may include:

[0209]

[0210] Although the various components in ECR-glass are expressed as ranges, the total weight percentage of the composition is 100% by weight. In this case, the ECR-glass contains no or substantially no B2O3 or F2. Boron-free ECR-glass fibers can be used as Advantex. TM The fiberglass was purchased from Owens Corning.

[0211] H-glass and its preparation method are disclosed in US11214512, the entire contents of which are incorporated herein by reference. The composition of H-glass may include:

[0212] 55.0% to 60.4% by weight of SiO2;

[0213] Al2O3 in amounts ranging from 19.0 wt% to 25.0 wt%;

[0214] 7% to 12.0% by weight of CaO;

[0215] 8.0% to 15.0% by weight of MgO;

[0216] 0% to 1.0% by weight of Na₂O; and

[0217] From 0.0% to 1.5% by weight of TiO2, expressed as a weight percentage based on the total weight of the composition.

[0218] The weight percentage ratio of Al2O3 / MgO is less than 2.0, the combined amount of SiO2, Al2O3, MgO and CaO is at least 98% by weight and less than 99.5% by weight, the total amount of B2O3, Li2O and fluorine is less than 0.2% by weight, and the glass composition has a fiberization temperature of not more than 2,500℉.

[0219] The composition of H glass may contain 19.5% to 21% by weight of Al2O3.

[0220] The combined amount of MgO and CaO in H glass is greater than 20% by weight.

[0221] The combined amount of MgO and CaO in H glass is less than 22% by weight.

[0222] The weight percentage ratio of Al2O3 / MgO in H glass is no greater than 1.8.

[0223] The combined amount of Fe2O3, TiO2, K2O and Na2O in H glass is less than 1.5% by weight.

[0224] The H glass composition contains no or substantially no B2O3.

[0225] The H-glass composition does not contain Li2O.

[0226] The weight of glass fiber in the precursor mat can range from about 30 gsm (grams per square meter) to about 170 gsm. The weight of glass fiber in the precursor mat can range from about 40 gsm to about 150 gsm. The weight of glass fiber in the precursor mat can be ≥ about 40 gsm. The weight of glass fiber in the precursor mat can be ≥ about 45 gsm. The weight of glass fiber in the precursor mat can be ≥ about 50 gsm. The weight of glass fiber in the precursor mat can be ≥ about 55 gsm. The weight of glass fiber in the precursor mat can be ≥ about 60 gsm.

[0227] The weight of glass fiber in the precursor mat can be ≤170 gsm. The weight of glass fiber in the precursor mat can be ≤165 gsm. The weight of glass fiber in the precursor mat can be ≤160 gsm. The weight of glass fiber in the precursor mat can be ≤155 gsm. The weight of glass fiber in the precursor mat can be ≤150 gsm. The weight of glass fiber in the precursor mat can be ≤140 gsm. The weight of glass fiber in the precursor mat can be ≤135 gsm. The weight of glass fiber in the precursor mat can be ≤130 gsm.

[0228] The weight of glass fiber in the precursor mat can range from about 60 gsm to about 130 gsm.

[0229] The weight of glass fiber in the precursor mat can be approximately 65 gsm.

[0230] During the manufacture of the coated nonwoven fiber felt, a first binder and a coating composition are applied in two separate stages. The first binder or a combination thereof is applied first during the formation of the precursor felt, and the coating composition (containing an aqueous composition as defined herein) is applied secondly during the formation of the final coated nonwoven fiber felt.

[0231] The first binder is selected from one or more (e.g., 1, 2, 3, 4, 5 or more) urea-formaldehyde resins, such as modified urea-formaldehyde resins.

[0232] Alternatively, the first adhesive may be selected from formaldehyde-free (or formaldehyde-free (“NAF”) adhesives. Formaldehyde-free adhesives are environmentally friendly, i.e., “green”.

[0233] The first adhesive may be selected from one or more (e.g., 1, 2, 3, 4, 5 or more) polycarboxylate adhesives, polyvinyl alcohol adhesives or combinations thereof.

[0234] The first binder may be a water-soluble or water-dispersible binder. The binder may be a water-soluble binder. The binder may be a water-dispersible binder. The binder composition may contain one or more water-based emulsions or solutions.

[0235] Polycarboxylate binders can be homopolymers or copolymers prepared from one or more (e.g., 1, 2, 3, 4, 5, or more) unsaturated carboxylic acid compounds, including, but not limited to, acrylic acid, methacrylic acid, crotonic acid, isocrotonic acid, maleic acid, cinnamic acid, 2-methylmaleic acid, itaconic acid, 2-methylitaconic acid, α,β-methyleneglutaric acid, etc. Methods for polymerizing these acids are known to those skilled in the art. In this case, the polycarboxylate binder is a homopolymer or copolymer containing at least one or more (e.g., 1, 2, 3, 4, or 5) repeating units, and each repeating unit contains a -COOH group.

[0236] Alternatively, the polycarboxylate binder may be prepared from unsaturated acid anhydrides, including, but not limited to, maleic anhydride, methacrylic anhydride, and mixtures thereof. Methods for polymerizing these anhydrides are known to those skilled in the art. In this case, the polycarboxylate binder is a homopolymer or copolymer comprising at least one or more (e.g., 1, 2, 3, 4, or 5) repeating units, and each repeating unit or each repeating unit comprises a -CO-O-CO- group.

[0237] Polycarboxylate binders may also comprise homopolymers or copolymers prepared from one or more (e.g., 1, 2, 3, 4, 5, or more) unsaturated carboxylic acid ester compounds, including, but not limited to, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, methyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, glycidyl methacrylate, vinyl acetate, etc. Methods for preparing these polymers are known to those skilled in the art. In this case, the polycarboxylate binder is a homopolymer or copolymer comprising at least one or more (e.g., 1, 2, 3, 4, or 5) repeating units, and each repeating unit comprises a -COOR group, and R is suitably selected from the group consisting of methyl, ethyl, butyl (n-, iso-, or tert-) and 2,3-epoxypropyl.

[0238] When a polycarboxylate binder comprises a mixture of polymers of unsaturated carboxylic acids (e.g., homopolymers or copolymers) (e.g., polyacrylic acid binders) and polymers of unsaturated carboxylic acid esters (e.g., homopolymers or copolymers) (e.g., polymethyl methacrylate), the weight percentage ratio of the polymer of the unsaturated carboxylic acid to the polymer of the unsaturated carboxylic acid ester is in the range of about 1 wt% : about 0.01 wt% to about 1 wt% : about 1 wt% of the total solids in the binder composition. The weight percentage ratio of the polymer of the unsaturated carboxylic acid to the polymer of the unsaturated carboxylic acid ester is in the range of about 1 wt% : about 0.1 wt% to about 1 wt% : about 0.8 wt% of the total solids in the binder composition. The weight percentage ratio of the polymer of the unsaturated carboxylic acid to the polymer of the unsaturated carboxylic acid ester is in the range of about 1 wt% : about 0.2 wt% to about 1 wt% : about 0.5 wt% of the total solids in the binder composition. The weight % ratio of the polymer of unsaturated carboxylic acid (e.g., polyacrylic acid adhesive) to the polymer of unsaturated carboxylic acid ester (e.g., polymethyl methacrylate) may be about 1 wt% of the total solids in the adhesive composition: about 0.4 wt%.

[0239] Polycarboxylate binders can be homopolymers or copolymers of polyacrylic acid. Polycarboxylate binders are homopolymers of polyacrylic acid, meaning the polymer is synthesized from acrylic acid. The weight-average molecular weight (Mi) of polycarboxylate binders (such as polyacrylic acid binders or polymethyl methacrylate binders) is... W It can be less than 10,000 g / mol, such as less than 5,000 g / mol, and for example, about 3,000 g / mol or less, such as about 2,000 g / mol.

[0240] Polycarboxylate binders may contain polymethyl methacrylate.

[0241] Polycarboxylate binders may contain polyacrylic acid and polymethyl methacrylate.

[0242] The pH of the first adhesive can be low, for example, about 3 or less, such as about 2.5 or less, such as about 2 or less. The pH of the adhesive can be adjusted by adding a suitable acid (such as sulfuric acid). A low pH of the adhesive can provide processing advantages. Examples of processing advantages include a reduction in curing temperature or time. The pH of the first adhesive can be from about pH 2 to about pH 3.

[0243] The first binder or combination thereof may additionally contain a polyol comprising at least two hydroxyl groups. Any suitable polyol may be used, provided that it is sufficiently non-volatile to remain substantially usable for reaction with the polyacids in the composition during heating and curing operations. The polyol may be a compound with a molecular weight of less than about 1000 and containing at least two hydroxyl groups, such as ethylene glycol, glycerol, pentaerythritol, trimethylolpropane, sorbitol, sucrose, glucose, resorcinol, catechol, pyrogallol, ethylene glycol urea, 1,4-cyclohexanediol, diethanolamine, or triethanolamine.

[0244] Polyols can be glycerol.

[0245] When a polycarboxylate binder comprises a mixture of a polymer of unsaturated carboxylic acids (e.g., a homopolymer or copolymer) and a polyol, the weight percentage ratio of the unsaturated carboxylic acid polymer to the polyol can range from about 1 wt% to about 0.01 wt% to about 1 wt% to about 1 wt% of the total solids in the binder composition. The weight percentage ratio of the unsaturated carboxylic acid polymer to the polyol can range from about 1 wt% to about 0.1 wt% to about 1 wt% to about 0.8 wt% of the total solids in the binder composition. The weight percentage ratio of the unsaturated carboxylic acid polymer to the polyol can range from about 1 wt% to about 0.2 wt% to about 1 wt% to about 0.5 wt% of the total solids in the binder composition. The weight percentage ratio of the unsaturated carboxylic acid polymer (e.g., a polyacrylic acid binder) to the polyol (e.g., glycerol) can be about 1 wt% to about 0.3 wt% of the total solids in the binder composition, such as about 1 wt% to about 0.25 wt% of the total solids in the binder composition.

[0246] The first binder may be a combination of polyacrylic acid, polymethyl methacrylate, and glycerin. The first binder may be a combination of (a) polyacrylic acid and glycerin, and (b) polymethyl methacrylate latex. The weight percentage ratio of polyacrylic acid to glycerin may be approximately 75% to approximately 25% of the total solids in the binder composition. The ratio of (a):(b) may be approximately 75% to approximately 25% of the total solids in the binder composition. The final weight percentage ratio of polyacrylic acid:glycerin:polymethyl methacrylate may be approximately 56%: approximately 19%: approximately 25% of the total solids in the binder composition.

[0247] In some embodiments, the polyol does not contain a hydroxyalkylamide group. Examples of such polyols include, but are not limited to, bis[N,N-di(hydroxyethyl)]hexamethylenediamine.

[0248] The first binder can be a polyvinyl alcohol (PVA) binder. PVA is a water-soluble polymer that can be manufactured by the hydrolysis (saponification) of polyvinyl acetate. PVA is typically described based on its degree of hydrolysis (hydrolysis %) and / or its weight-average molecular weight (Mw).

[0249] The weight-average molecular weight (M) of polyvinyl alcohol adhesive W It can be less than 10,000 g / mol, such as less than 5,000 g / mol, and for example, about 3,000 g / mol or less, such as about 2,000 g / mol.

[0250] Polyvinyl alcohol adhesives may have a hydrolysis percentage of approximately 80%. Hydrolysis percentage may be approximately 85%. Hydrolysis percentage may be approximately 90%. Hydrolysis percentage may be approximately 91%. Hydrolysis percentage may be approximately 92%. Hydrolysis percentage may be approximately 93%. Hydrolysis percentage may be approximately 94%. Hydrolysis percentage may be approximately 95%. Hydrolysis percentage may be approximately 96%. Hydrolysis percentage may be approximately 97%. Hydrolysis percentage may be approximately 98%. Hydrolysis percentage may be approximately 99%.

[0251] The hydrolysis percentage can be ≥98% to 99%. In this case, the polyvinyl alcohol binder has high purity and is particularly suitable for coated nonwoven fiber mats in gypsum board.

[0252] Polyvinyl alcohol binders can be liquid or solid. When polyvinyl alcohol binders are in powder form, they can be co-cast with glass fiber blends in an aqueous solution.

[0253] Polycarboxylate binders can be copolymers prepared from one or more (e.g., 1, 2, 3, 4, 5 or more) unsaturated carboxylic acid compounds and one or more (e.g., 1, 2, 3, 4, 5 or more) aryl vinyl compounds. Unsaturated carboxylic acids include, but are not limited to, acrylic acid, methacrylic acid, crotonic acid, isocrotonic acid, maleic acid, cinnamic acid, 2-methylmaleic acid, itaconic acid, 2-methylitaconic acid, α,β-methyleneglutaric acid, etc. Aryl vinyl compounds include, but are not limited to, styrene, methylstyrene (2-, 3- or 4-), ethylstyrene (2-, 3- or 4-), n-butylstyrene (2-, 3- or 4-), isobutylstyrene (2-, 3- or 4-), tert-butylstyrene (2-, 3- or 4-), α-methylstyrene (also known as isopropylbenzene), and β-methylstyrene (also known as acrylonitrile). Methods for preparing these copolymers are known to those skilled in the art. In this case, the polycarboxylic acid binder is a copolymer comprising: (a) repeating units containing -COOH groups and (b) repeating units containing substituted or unsubstituted styrene groups.

[0254] The first binder is a styrene-acrylic latex. In this case, the copolymer is prepared from an unsaturated carboxylic acid (which is acrylic acid) and an aryl vinyl compound (which is styrene).

[0255] The weight percentage of the first adhesive or its combination thereof may range from about 5% to about 50% of the total solids in the precursor felt. The weight percentage of the first adhesive or its combination thereof may range from about 10% to about 40% of the total solids in the precursor felt. The weight percentage of the first adhesive or its combination thereof may be greater than or equal to about 10% of the total solids in the precursor felt. The weight percentage of the first adhesive or its combination thereof may be greater than or equal to about 11% of the total solids in the precursor felt. The weight percentage of the first adhesive or its combination thereof may be greater than or equal to about 12% of the total solids in the precursor felt. The weight percentage of the first adhesive or its combination thereof may be greater than or equal to about 13% of the total solids in the precursor felt. The weight percentage of the first adhesive or its combination thereof may be greater than or equal to about 14% of the total solids in the precursor felt.

[0256] The weight percentage of the first adhesive or its combination may be less than or equal to about 35% of the total solids in the precursor felt. The weight percentage of the first adhesive or its combination may be less than or equal to about 30% of the total solids in the precursor felt. The weight percentage of the first adhesive or its combination may be less than or equal to about 25% of the total solids in the precursor felt.

[0257] The weight percentage of the first binder or combination thereof may be in the range of about 15% to about 25% of the total solids in the precursor felt.

[0258] The weight percentage of the first binder or its combination may be approximately 23% of the total solids in the precursor felt.

[0259] The amounts of binders, each thickener, inorganic fillers, dispersants, and optional additives (if any) may be described individually as a weight percentage of the total solids in the dried coating composition. The weight percentage of each component in the dried composition shall be summed to 100% by weight of the total solids in the dried coating composition.

[0260] The drying composition may contain a hydrophobic binder ranging from about 1% to about 15% by weight of the total solids in the drying composition. The drying composition may contain a hydrophobic binder ranging from about 3% to about 12% by weight of the total solids in the drying composition. The drying composition may contain a hydrophobic binder in an amount ≥ 3% by weight of the total solids in the drying composition. The drying composition may contain a hydrophobic binder in an amount ≥ 3.5% by weight of the total solids in the drying composition. The drying composition may contain a hydrophobic binder in an amount ≥ 4% by weight of the total solids in the drying composition. The drying composition may contain a hydrophobic binder in an amount ≥ 4.5% by weight of the total solids in the drying composition. The drying composition may contain a hydrophobic binder in an amount ≥ 5% by weight of the total solids in the drying composition. The drying composition may contain a hydrophobic binder in an amount ≥ 6% by weight of the total solids in the drying composition. The drying composition may contain a hydrophobic binder in an amount ≥ 6.5% by weight of the total solids in the drying composition. The drying composition may contain a hydrophobic binder in an amount ≥ 7% by weight of the total solids in the drying composition.

[0261] The drying composition may contain ≤12% by weight of a hydrophobic binder of the total solids in the drying composition. The drying composition may contain ≤11.5% by weight of a hydrophobic binder of the total solids in the drying composition. The drying composition may contain ≤11% by weight of a hydrophobic binder of the total solids in the drying composition. The drying composition may contain ≤10.5% by weight of a hydrophobic binder of the total solids in the drying composition. The drying composition may contain ≤10% by weight of a hydrophobic binder of the total solids in the drying composition. The drying composition may contain ≤9.5% by weight of a hydrophobic binder of the total solids in the drying composition. The drying composition may contain ≤9% by weight of a hydrophobic binder of the total solids in the drying composition. The drying composition may contain ≤8.5% by weight of a hydrophobic binder of the total solids in the drying composition. The drying composition may contain ≤8% by weight of a hydrophobic binder of the total solids in the drying composition.

[0262] The dried composition may contain a hydrophobic binder in the range of about 5% to about 10% by weight of the total solids in the dried composition (such as about 7% to about 9% by weight).

[0263] The dried composition may contain approximately 0.05% by weight to approximately 1% by weight of the total solids in the dried composition, which has a large M W Thickener. The dried composition may contain an amount of thickener with a greater M, which is ≥0.1% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain about 0.12% by weight of a thickener with a large M. W Thickener. The dried composition may contain an amount of thickener with a greater M, which is approximately 0.14% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of thickener with a greater M, which is approximately 0.16% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain about 0.18% by weight of a thickener with a large M. W Thickener. The dried composition may contain about 0.2% by weight of a thickener with a large M. W Thickener. The dried composition may contain an amount of thickener with a greater M, which is approximately 0.22% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of thickener with a greater M, which is approximately 0.23% by weight of the total solids in the dried composition. W Thickener.

[0264] The dried composition may contain an amount of a large M, which is ≤0.5% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of thickener with a large M, ≤0.4% by weight of the total solids in the dried composition.W Thickener. The dried composition may contain an amount of thickener with a large M, ≤0.38% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of thickener with a large M, ≤0.36% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of thickener with a large M, ≤0.34% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of thickener with a large M, ≤0.32% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of thickener with a larger M, ≤0.3% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of thickener with a large M, ≤0.28% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of thickener with a large M, ≤0.26% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of thickener with a large M, ≤0.24% by weight of the total solids in the dried composition. W Thickener.

[0265] The dried composition may contain about 0.2% by weight to about 0.4% by weight of the total solids in the dried composition (such as about 0.2% by weight to about 0.3% by weight, for example 0.23% by weight) of a substance with a large M W Thickener.

[0266] The dried composition may contain about 0.05% by weight to about 1% by weight of the total solids in the dried composition, having a smaller M W Thickener. The dried composition may contain an amount of a small amount of thickener having a thickness of about 0.06% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of a small amount of thickener having a thickness of about 0.07% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of a small amount of thickener having a thickness of about 0.08% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of a small amount of thickener having a thickness of about 0.09% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of a small amount of thickener having a weight of about 0.1% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of a small amount of thickener having a thickness of about 0.11% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of a small amount of thickener having a thickness of about 0.12% by weight of the total solids in the dried composition.W Thickener.

[0267] The dried composition may contain an amount of less than 1% by weight of the total solids in the dried composition, having a smaller M W Thickener. The dried composition may contain an amount of a small amount of thickener having a thickness of about 0.5% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of a small amount of thickener with a weight of about 0.4% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of a small amount of thickener having a thickness of about 0.3% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of a small amount of thickener having a weight of about 0.2% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of a small amount of thickener having a thickness of about 0.18% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of a small amount of thickener having a thickness of about 0.16% by weight of the total solids in the dried composition. W Thickener. The dried composition may contain an amount of a small amount of thickener having a thickness of about 0.15% by weight of the total solids in the dried composition. W Thickener.

[0268] The dried composition may contain, for example, 0.13% by weight of a component with a smaller M, in the range of about 0.12% by weight to about 0.14% by weight of the total solids in the dried composition. W Thickener.

[0269] The drying composition may contain inorganic fillers ranging from about 50% to about 98% by weight of the total solids in the drying composition. The drying composition may contain fillers in an amount ≥ about 50% by weight of the total solids in the drying composition. The drying composition may contain fillers in an amount ≥ about 55% by weight of the total solids in the drying composition. The drying composition may contain fillers in an amount ≥ about 60% by weight of the total solids in the drying composition. The drying composition may contain fillers in an amount ≥ about 65% by weight of the total solids in the drying composition. The drying composition may contain fillers in an amount ≥ about 70% by weight of the total solids in the drying composition. The drying composition may contain fillers in an amount ≥ about 75% by weight of the total solids in the drying composition. The drying composition may contain fillers in an amount ≥ about 80% by weight of the total solids in the drying composition. The drying composition may contain fillers in an amount ≥ about 85% by weight of the total solids in the drying composition.

[0270] The drying composition may contain inorganic filler in an amount of ≤98% by weight of the total solids in the drying composition. The drying composition may contain filler in an amount of ≤97.5% by weight of the total solids in the drying composition. The drying composition may contain filler in an amount of ≤97% by weight of the total solids in the drying composition. The drying composition may contain filler in an amount of ≤96.5% by weight of the total solids in the drying composition. The drying composition may contain filler in an amount of ≤96% by weight of the total solids in the drying composition. The drying composition may contain filler in an amount of ≤95.5% by weight of the total solids in the drying composition.

[0271] The dried composition may contain inorganic fillers ranging from about 88% to about 95% by weight of the total solids in the dried composition (such as about 90% to about 92% by weight).

[0272] The drying composition may contain a dispersant in the range of about 0.001% to about 0.15% by weight of the total solids in the drying composition (e.g., about 0.001% to about 0.08% by weight of the total solids in the drying composition). The drying composition may contain a dispersant in an amount ≥ about 0.001% by weight of the total solids in the drying composition. The drying composition may contain a dispersant in an amount ≥ about 0.01% by weight of the total solids in the drying composition. The drying composition may contain a dispersant in an amount ≥ about 0.02% by weight of the total solids in the drying composition. The drying composition may contain a dispersant in an amount ≥ about 0.03% by weight of the total solids in the drying composition. The drying composition may contain a dispersant in an amount ≥ about 0.04% by weight of the total solids in the drying composition. The drying composition may contain a dispersant in an amount ≥ about 0.05% by weight of the total solids in the drying composition. The drying composition may contain a dispersant in an amount ≥ about 0.06% by weight of the total solids in the drying composition.

[0273] The drying composition may contain a dispersant in an amount of ≤0.13% by weight of the total solids in the drying composition. The drying composition may contain a dispersant in an amount of ≤0.12% by weight of the total solids in the drying composition. The drying composition may contain a dispersant in an amount of ≤0.11% by weight of the total solids in the drying composition. The drying composition may contain a dispersant in an amount of ≤0.1% by weight of the total solids in the drying composition. The drying composition may contain a dispersant in an amount of ≤0.09% by weight of the total solids in the drying composition. The drying composition may contain a dispersant in an amount of ≤0.08% by weight of the total solids in the drying composition. The drying composition may contain a dispersant in an amount of ≤0.07% by weight of the total solids in the drying composition.

[0274] The dried composition may contain a dispersant in the range of about 0.06% by weight to about 0.07% by weight of the total solids in the dried composition (such as about 0.065% by weight or 0.07% by weight).

[0275] If the coating contains a biocide, the drying composition may contain a biocide in the range of about 0.001% by weight to about 0.08% by weight of the total solids in the drying composition. The drying composition may contain a biocide in an amount ≥ about 0.001% by weight of the total solids in the drying composition. The drying composition may contain a biocide in an amount ≥ about 0.01% by weight of the total solids in the drying composition. The drying composition may contain a biocide in an amount ≥ about 0.02% by weight of the total solids in the drying composition.

[0276] The drying composition may contain a biocide in an amount of ≤0.13% by weight of the total solids in the drying composition. The drying composition may contain a biocide in an amount of ≤0.12% by weight of the total solids in the drying composition. The drying composition may contain a biocide in an amount of ≤0.11% by weight of the total solids in the drying composition. The drying composition may contain a biocide in an amount of ≤0.1% by weight of the total solids in the drying composition. The drying composition may contain a biocide in an amount of ≤0.09% by weight of the total solids in the drying composition. The drying composition may contain a biocide in an amount of ≤0.08% by weight of the total solids in the drying composition.

[0277] The dried composition may contain a biocide in the range of about 0.03% by weight to about 0.07% by weight of the total solids in the dried composition (such as about 0.05% by weight).

[0278] The dried composition may contain other optional additives, such as those described herein, in amounts of about 0.01% to about 0.08% by weight (such as about 0.01% to about 0.06% by weight) of the total solids in the dried composition.

[0279] Alternatively, the dried composition may be free of other optional additives.

[0280] The weight of the drying coating composition can range from about 130 gsm (grams per square meter) to about 300 gsm. The weight of the drying coating composition can range from about 180 gsm to about 270 gsm. The weight of the drying coating composition can be ≥ about 170 gsm. The weight of the drying coating composition can be ≥ about 180 gsm. The weight of the drying coating composition can be ≥ about 190 gsm. The weight of the drying coating composition can be ≥ about 200 gsm. The weight of the drying coating composition can be ≥ about 210 gsm.

[0281] The weight of the dried coating composition can be ≤ about 290 gsm. The weight of the dried coating composition can be ≤ about 280 gsm. The weight of the dried coating composition can be ≤ about 270 gsm. The weight of the dried coating composition can be ≤ about 260 gsm.

[0282] The weight of the drying coating composition can be in the range of about 220 gsm to about 260 gsm, such as about 254 gsm.

[0283] The total weight of (dry) coated nonwoven fiber mats can range from about 200 gsm (grams per square meter) to about 430 gsm. The total weight of coated nonwoven fiber mats can range from about 250 gsm to about 380 gsm. The total weight of coated nonwoven fiber mats can be ≥ about 260 gsm. The total weight of coated nonwoven fiber mats can be ≥ about 270 gsm. The total weight of coated nonwoven fiber mats can be ≥ about 280 gsm. The total weight of coated nonwoven fiber mats can be ≥ about 285 gsm. The total weight of coated nonwoven fiber mats can be ≥ about 290 gsm. The total weight of coated nonwoven fiber mats can be ≥ about 300 gsm.

[0284] The total weight of the coated nonwoven fiber mat can be ≤ approximately 380 gsm. The total weight of the coated nonwoven fiber mat can be ≤ approximately 370 gsm. The total weight of the coated nonwoven fiber mat can be ≤ approximately 360 gsm. The total weight of the coated nonwoven fiber mat can be ≤ approximately 355 gsm. The total weight of the coated nonwoven fiber mat can be ≤ approximately 350 gsm. The total weight of the coated nonwoven fiber mat can be ≤ approximately 340 gsm.

[0285] The total weight of coated nonwoven fiber mats can range from about 285 gsm to about 355 gsm, such as about 300 gsm to 330 gsm.

[0286] The thickness (or caliper thickness) of the coated nonwoven fiber mat can be measured according to ASTM D1777. According to ASTM D1777, the thickness of the coated nonwoven fiber mat can range from approximately 0.3 mm to approximately 2 mm. The thickness of the coated nonwoven fiber mat can be ≥0.3 mm. The thickness of the coated nonwoven fiber mat can be ≥0.35 mm. The thickness of the bonded nonwoven fiber mat can be ≥0.4 mm. The thickness of the coated nonwoven fiber mat can be ≥0.45 mm. The thickness of the coated nonwoven fiber mat can be ≥0.5 mm. The thickness of the coated nonwoven fiber mat can be ≥0.55 mm. The thickness of the coated nonwoven fiber mat can be ≥0.6 mm.

[0287] According to ASTM D1777, the thickness of coated nonwoven fiber mats can be ≤2mm. The thickness of coated nonwoven fiber mats can be ≤1.7mm. The thickness of coated nonwoven fiber mats can be ≤1.6mm. The thickness of coated nonwoven fiber mats can be ≤1.5mm. The thickness of coated nonwoven fiber mats can be ≤1.4mm. The thickness of coated nonwoven fiber mats can be ≤1.3mm. The thickness of coated nonwoven fiber mats can be ≤1.2mm. The thickness of coated nonwoven fiber mats can be ≤1.1mm. The thickness of coated nonwoven fiber mats can be ≤1mm. The thickness of coated nonwoven fiber mats can be ≤0.9mm. The thickness of coated nonwoven fiber mats can be ≤0.8mm.

[0288] According to ASTM D1777, the thickness of coated nonwoven fiber mat can range from about 0.65 mm to about 0.75 mm.

[0289] The Cobb test measures the ability of coated nonwoven fabric to resist water penetration. A lower Cobb value is better, as this indicates greater hydrophobicity of the coated nonwoven fabric.

[0290] When measured according to European standard EN20535 (which applies to nonwoven fiber mats), coated nonwoven fiber mats may have a strength of ≤100 g / m³. 2 The Cobb value. When measured according to European standard EN20535 (which applies to nonwoven fiber mats), coated nonwoven fiber mats can have a Cobb value of approximately 10 g / m². 2 Approximately 60g / m 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≥10 g / m³. 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≥15 g / m³. 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≥20 g / m³. 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≥25 g / m³. 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≥30 g / m³. 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≥35 g / m³. 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≥40 g / m³. 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≥45 g / m³. 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≥46 g / m³. 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≥47 g / m³. 2 The Cobb value.

[0291] When measured according to European standard EN20535 (which applies to nonwoven fiber mats), coated nonwoven fiber mats may have a strength of ≤100 g / m³. 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≤approximately 90 g / m³. 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≤approximately 80 g / m³. 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≤approximately 70 g / m³. 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≤approximately 60 g / m³. 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≤approximately 50 g / m³. 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≤approximately 49 g / m³. 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≤approximately 48 g / m³. 2 The Cobb value. Coated nonwoven fiber mats can have a Cobb value of ≤approximately 47 g / m³. 2 The Cobb value.

[0292] When measured according to European standard EN20535 (which applies to nonwoven fiber mats), coated nonwoven fiber mats can have approximately 45 g / m². 2 Approximately 50g / m 2 Cobb values, such as approximately 47 g / m³ 2 .

[0293] Air permeability testing measures the airflow through a region of a substrate, such as the coated nonwoven felt of this invention. The coated nonwoven felt may have air permeability as measured according to ASTM D737.

[0294] Method for manufacturing coated nonwoven fiber mat

[0295] The precursor felt is prepared by co-casting fibers and a first binder before impregnating the precursor felt.

[0296] In another aspect, the present invention provides a method for manufacturing coated nonwoven fiber mat, the method comprising the following steps:

[0297] (v) Providing a precursor mat comprising glass fiber and a first adhesive;

[0298] (vi) Deposit the aqueous composition as described herein onto the precursor felt;

[0299] (vii) The precursor felt is coated with the aqueous composition using a roller-lined scraper technique.

[0300] When the precursor felt and the aqueous composition pass through the predetermined gap between the scraper and the roller,

[0301] The scraper comes into contact with the aqueous composition.

[0302] The aqueous composition exhibits shear thinning upon contact with the scraper, and

[0303] The precursor felt is coated with the aqueous composition; and

[0304] (viii) Dry the coated precursor felt to form the coated nonwoven fiber felt.

[0305] The precursor felt can be prepared by a method comprising the following steps:

[0306] (i) Provides an aqueous mixture comprising glass fiber and a first binder;

[0307] (ii) forming a dispersion of the aqueous mixture;

[0308] (iii) Deposit the aqueous dispersion to form a wet-laid fiber web of glass fibers and a first binder;

[0309] (iv) Dry the wet-laid fiber web of the glass fiber and the first binder to form the precursor felt.

[0310] The step used to form the precursor felt can also be called the "co-casting" method. This is because the aqueous mixture of glass fibers is formed together with the first binder.

[0311] Glass fiber, a first adhesive (or a combination thereof), a precursor mat, and an aqueous composition are as described above.

[0312] Alternatively, the precursor felt may be prepared by a method comprising the following steps:

[0313] (i) Provide an aqueous mixture containing glass fibers;

[0314] (ii) Depositing the aqueous mixture to form a wet-laid fiber web of glass fibers;

[0315] (iii) Applying an aqueous solution or dispersion of the first binder to the wet-laid fiber web of the glass fiber to form a wet-laid fiber web of glass fiber and the first binder;

[0316] (iv) Dry the wet-laid fiber web of the glass fiber and the first binder to form the precursor felt.

[0317] The first adhesive can be applied to the fiberglass mesh using a suitable adhesive applicator (such as a sprayer or curtain coater).

[0318] Flexible precursor felts can be formed via a wet web-forming process. Nonwoven felts are formed via a wet web-forming process, which involves forming an aqueous dispersion, slurry, or mixture of discrete fibers in a mixing tank filled with various optional components (sometimes referred to as white water). Thus, the aqueous mixture comprises glass fibers, a first binder (or a combination thereof), and water, as well as optional other components such as surfactants, viscosity modifiers, defoamers, lubricants, biocides, and / or other chemical reagents.

[0319] A dispersion of an aqueous mixture can be obtained by any suitable means, provided that a uniform or substantially uniform distribution of glass fibers is achieved in the aqueous medium. A uniform distribution of glass fibers can be achieved. Alternatively, a substantially uniform distribution of glass fibers can be achieved. The dispersion can be obtained by high-shear mixing equipment, such as a rotor / stator mixer.

[0320] The first binder (or combination thereof) may optionally contain conventional additives as described above for improving process and product performance, such as dyes, oils, biocides, fillers, colorants, UV stabilizers, coupling agents (e.g., aminosilanes), lubricants, wetting agents, surfactants and / or antistatic agents.

[0321] The first binder (or combination thereof) may be added at any suitable point during the preparation of the aqueous mixture. For example, the binder (or combination thereof) may be added before, after, or simultaneously with the glass fiber.

[0322] The first binder can be a liquid or a solid. When the first binder is a powder, the powdered binder can promote co-casting with glass fibers in an aqueous solution.

[0323] The aqueous fiber dispersion or slurry can then be processed into a wet-laid felt using any number of conventional methods known in the art. For example, the aqueous fiber dispersion or slurry can be deposited onto a moving screen or conveyor, where most of the water is drained away, leaving a randomly oriented fiber web. Water can be removed from the web using conventional vacuum or air suction systems.

[0324] Once the binder is applied to the wet-laid fiber web of glass fiber and the first binder, the wet-laid fiber web is passed through at least one drying oven to remove residual water and cure the binder composition. The fiber web may be further dried by a vacuum chamber or other drying means to provide the desired fiber web.

[0325] The forming precursor mat emerging from the oven is an aggregate of randomly oriented, dispersed individual glass fibers. The fiber mat can be wound onto a take-up roller for storage or subsequent use.

[0326] The precursor felt is coated essentially or entirely with an aqueous composition as defined above.

[0327] The aqueous compositions of the present invention are prepared by any suitable method, such as mixing each component with water and an aqueous hydrophobic binder.

[0328] The coated nonwoven fiber felt is asymmetrical. "Asymmetrical" means that the aqueous composition of the present invention does not completely impregnate the precursor felt. Instead, the aqueous composition is coated only on one side of the precursor felt or located on one side of the precursor felt. In this respect, the aqueous composition will be detectable on the coated side of the precursor felt, but not on the other side of the felt (uncoated).

[0329] The coated precursor felt is then dried to form a coated nonwoven fabric felt. Typically, the coated precursor felt can be passed through at least one drying oven to remove any residual water and cure the binder. The felt can be further dried using a vacuum bath or other drying means to provide the coated nonwoven fabric felt as described above.

[0330] When measured according to European standard EN20535 (which applies to nonwoven fiber mats), coated nonwoven fiber mats may have a g / m² content of less than 100 g / m². 2 The Cobb value.

[0331] Printed coated nonwoven fiber felt

[0332] The coated nonwoven felt of the present invention is opaque and color-stable. Therefore, it does not require printing with, for example, ink or other non-removable fluids suitable for printing. However, if desired, the method for manufacturing the coated nonwoven felt may further include applying a liquid ink formulation to a first surface, a second surface, or both of the first and second surfaces of the coated nonwoven felt to coat or impregnate the first surface, the second surface, or both of the first and second surfaces of the coated nonwoven felt; and drying the liquid ink formulation to form a coated nonwoven felt comprising a dried ink layer.

[0333] The liquid coating formulation can be applied to a first surface of the coated nonwoven fiber felt to coat or impregnate the first surface of the coated nonwoven fiber felt. The liquid coating formulation can be applied to a second surface of the coated nonwoven fiber felt to coat or impregnate the second surface of the coated nonwoven fiber felt. The liquid coating formulation can be applied to both the first and second surfaces of the coated nonwoven fiber felt to coat or impregnate both the first and second surfaces of the coated nonwoven fiber felt.

[0334] Methods for drying wet coated or impregnated nonwoven fiber mats to form a coated nonwoven fiber mat including a dried coating layer are known to those skilled in the art. These methods include, but are not limited to, drying at ambient temperature and pressure, drying in hot air, and drying using infrared technology.

[0335] In another aspect, the present invention provides a coated nonwoven fiber felt comprising:

[0336] The coated nonwoven fiber felt as described above, and

[0337] The first surface, the second surface, or both the first surface and the second surface include an ink layer.

[0338] Coated nonwoven fiber mats are as described in this article.

[0339] The first surface may include an ink layer. The second surface may include an ink layer. Both the first and second surfaces may include ink layers.

[0340] Applications of coated nonwoven fiber mats

[0341] When coated nonwoven fabric is produced using a wet web-forming process and an aqueous fiber dispersion or slurry is deposited onto a moving screen or conveyor, the resulting coated nonwoven fabric typically has a smooth surface (the surface in contact with the moving screen or conveyor) and a non-smooth surface (the surface not in contact with the moving screen or conveyor). The smooth surface is typically the exposed surface. For example, when coated nonwoven fabric is attached to a building panel, the smooth surface faces the interior of the room, while the non-smooth surface is attached to the panel. As an alternative application, coated nonwoven fabric can be used in wall covering applications.

[0342] In another aspect, the present invention provides a building panel comprising:

[0343] A first surface and a second surface opposite to the first surface,

[0344] A coated nonwoven fiber mat, the coated nonwoven fiber mat being adhered to the first surface, the second surface, or both the first surface and the second surface, and

[0345] The coated nonwoven fiber felt is as described above.

[0346] Coated nonwoven fiber mats are as described in this article.

[0347] The coated nonwoven fiber felt can be a cladding in a building panel, i.e., the cladding is adhered to a first surface, a second surface, or both the first and second surfaces to form a building panel.

[0348] The building panels can be freely selected from a combination of ceiling tiles, gypsum board, building panels, insulation panels, and flooring. The building panels can be gypsum board.

[0349] The adhesion of the coated nonwoven fiber felt of the present invention to the gypsum core can be determined according to ASTM D4541. In this regard, a higher adhesion value is better, as this indicates that the coated nonwoven fiber felt adheres firmly to the gypsum core.

[0350] When measured according to ASTM D4541, coated nonwoven fiber mats may have an adhesive value of ≥ about 420 Newtons. When measured according to ASTM D4541, coated nonwoven fiber mats may have an adhesive value of ≥ about 420 N to ≤ about 650 N. Coated nonwoven fiber mats may have an adhesive value of ≥ about 430 N. Coated nonwoven fiber mats may have an adhesive value of ≥ about 435 N. Coated nonwoven fiber mats may have an adhesive value of ≥ about 440 N. Coated nonwoven fiber mats may have an adhesive value of ≥ about 450 N. Coated nonwoven fiber mats may have an average value of ≥ about 460 N. Coated nonwoven fiber mats may have an adhesive value of ≥ about 470 N. Coated nonwoven fiber mats may have an adhesive value of ≥ about 480 N. Coated nonwoven fiber mats may have an adhesive value of ≥ about 490 N. Coated nonwoven fiber mats can have an adhesion value of ≥500N. Coated nonwoven fiber mats can have an adhesion value of ≥505N.

[0351] When measured according to ASTM D4541, coated nonwoven fiber mats may have an adhesive value of ≤650 N. Coated nonwoven fiber mats may have an adhesive value of ≤625 N. Coated nonwoven fiber mats may have an adhesive value of ≤600 N. Coated nonwoven fiber mats may have an adhesive value of ≤575 N. Coated nonwoven fiber mats may have an adhesive value of ≤560 N. Coated nonwoven fiber mats may have an adhesive value of ≤550 N. Coated nonwoven fiber mats may have an average value of ≤540 N. Coated nonwoven fiber mats may have an adhesive value of ≤530 N. Coated nonwoven fiber mats may have an adhesive value of ≤520 N. Coated nonwoven fiber mats may have an adhesive value of ≤510 N.

[0352] When measured according to ASTM D4541, coated nonwoven fiber mats may have an adhesion of ≥ about 505 N to ≤ about 510 N, such as about 508 N.

[0353] Embodiments and / or optional features of the invention have been described above. Unless the context otherwise requires, any aspect of the invention may be combined with any other aspect of the invention. Unless the context otherwise requires, any embodiment or optional feature of any aspect may be combined with any aspect of the invention, alone or in combination.

[0354] The invention will now be further described with reference to the following embodiments, which are intended to illustrate rather than limit the scope of the invention.

[0355] Example

[0356] Raw materials used

[0357] The following commercially available materials were used in the embodiments:

[0358]

[0359] Test methods

[0360] Determination of the weight-average molecular weight (M) of acrylic thickener W )

[0361] GPC method in dimethylacetamide (DMAc)

[0362] Acrylic thickener samples can be analyzed using an Agilent 1260 Infinity MDS instrument under the following conditions:

[0363] • Column assembly: 2 × PolarGel M columns (300mm × 7.5mm)

[0364] • Injection volume: 100 μl

[0365] • Eluent: DMAc + 0.9% LiCl

[0366] • Detector: Differential refractive index (RI)

[0367] • Column temperature: 40℃

[0368] • Detector temperature: 40℃

[0369] • Flow rate: 1.0 ml / min

[0370] • Use polystyrene standards for calibration to assess molecular weight.

[0371] Aqueous Composition

[0372] Measuring the rheological properties of the aqueous composition to determine its thixotropy and flow profile:

[0373] • Rheometry Thixotropy: To evaluate the thixotropic properties of the aqueous composition, different levels of shear gradient were sequentially applied at 25°C. Specifically, the first stage consisted of the following steps: allowing the product to remain almost stationary, and then applying a shear gradient of 0.01 s... -1 Very low shear for 5 minutes, then suddenly subject the product to strong shear (1000s). -1The average viscosity was evaluated after 1 minute. At the end of the specified time, the product was returned to the level equivalent to the first stage (0.01s). -1 The product undergoes low shear stress for approximately 30 minutes. The thixotropic properties of the product are visible during this final step: the product will take either more or less time to recover from the 0.01s observed in the first stage. -1 The obtained viscosity level.

[0374] • Rheometer flow profile: The flow profile was determined using a fresh sample of the aqueous composition at 25°C over a time period of 200 seconds, with a range of 0.01 s. -1 up to 1000s -1 The hysteresis flow curve was determined between shear and shear using a logarithmic ramp of 10 every 20 seconds, and then over a 200-second time period from 1000 s. -1 up to 0.01s -1 The shear rate is measured using a logarithmic ramp of 10 every 20 seconds. This measurement reveals the viscosity level, and thus the mechanical stress required to make the product flow at different shear intensities. The results are presented as a viscosity versus shear graph.

[0375] Viscosity of thickener aqueous solution

[0376] Preparation of TAFIGEL ® 2% and 4% aqueous solutions of AP 11 were prepared. The solutions were made alkaline by adding a suitable base (e.g., aminomethylpropanol). The viscosity of the solutions at pH 8.2 and 10 was measured at 5 rpm and 100 rpm.

[0377] Preparation of TAFIGEL ® A 2% aqueous solution of AP 17. The solution was made alkaline by adding a suitable base (e.g., aminomethylpropanol). The viscosity of the solution at pH 8.5 and 10 was measured at 5 rpm and 100 rpm.

[0378]

[0379]

[0380] 2% aqueous solution

[0381] 4% aqueous solution

[0382] Coated nonwoven fiber mat

[0383] The following tests can be performed on coated nonwoven fiber mats:

[0384] • Breathability. Breathability testing is conducted according to ASTM D737.

[0385] • Longitudinal tensile strength. Longitudinal tensile strength was tested using a sample size of 300mm × 50mm.

[0386] • Cobb test. The Cobb value can be determined according to European standard EN20535 (which applies to nonwoven fiber mats).

[0387] plasterboard

[0388] When coated nonwoven fiber felt is bonded to gypsum board, its adhesion (pull-out head test) is performed according to ASTM D4541.

[0389] Preparation of aqueous compositions

[0390] Example 1 and Example 2

[0391] Two aqueous compositions were prepared as follows:

[0392]

[0393] According to the present invention

[0394] • Not based on this invention

[0395] Use a high-speed disc disperser, such as the Dispermat CN30 (Brant Industries), to mix the components in sequence.

[0396] As described in the test methods section above, the thixotropic behavior and flow profile of the aqueous composition were determined.

[0397] Example 3

[0398] Preparation of coated nonwoven fiber mat

[0399] A commercially available nonwoven fiber precursor mat (U 85 / 1) is available from Adfors. This precursor mat is a wet-laid glass mat.

[0400] The technical features of this precursor felt are:

[0401]

[0402] tolerance:

[0403] Width: ±3mm for precursor felt with trimmed edges.

[0404] For the precursor felt with untrimmed edges, the tolerance is ±12 mm.

[0405] Precursor felt is coated using a roller-blade coating process.

[0406] The precursor mat was coated with the aqueous compositions of Examples 1 and 2.

[0407] Roller-lined doctor blade coating is a technique in which the doctor blade is suspended above the roller and does not directly contact the substrate (i.e., the precursor felt). In this configuration, the coating thickness is controlled by the gap between the substrate and the doctor blade, which is determined by setting the gap between the roller and the blade.

[0408] The coated precursor felt was dried using an oven to form coated nonwoven fiber felt 1 (using the aqueous composition of Example 1) and coated nonwoven fiber felt 2 (using the aqueous composition of Example 2). The thin felts were dried to remove sufficient water so that the coated nonwoven fiber felts exhibited the desired properties.

[0409] The composition of the coated nonwoven fiber felt is as follows:

[0410]

[0411] The air permeability of the coated nonwoven felt of the present invention and a comparative coated nonwoven felt was measured using ASTM D737. The coated nonwoven felt was found to have comparable air permeability.

Claims

1. An aqueous composition for bonding nonwoven fiber mats, the composition comprising: • Water-based hydrophobic adhesives; • Two thickeners independently selected from acrylic polymers, One of the thickeners has a weight-average molecular weight of approximately 500,000 g / mol to approximately 1,000,000 g / mol, as determined by gel permeation chromatography. Another thickener has a weight-average molecular weight of about 100,000 g / mol to about 380,000 g / mol, as determined by gel permeation chromatography. •Inorganic fillers; • Dispersants; and •water; The aqueous hydrophobic adhesive is a copolymer of the following: i) a monomeric unit selected from ethylene tert-carbonate, its isomers, or mixtures thereof; and ii) at least one monomer unit selected from (meth)acrylic acid or (meth)acrylate.

2. The aqueous composition according to claim 1, wherein the thickener is independently selected from anionic acrylic polymers or hydrophobically modified acrylic polymers.

3. The aqueous composition according to claim 2, wherein the aqueous composition further comprises an amine.

4. The aqueous composition according to claim 3, wherein the amine is selected from the group consisting of: aqueous ammonium hydroxide or amino alcohol, optionally 2-amino-2-methyl-1-propanol, 2-dimethylaminoethanol, diethanolamine, 3-dimethylamino-1-propanol or N-methylethanolamine.

5. The aqueous composition according to any one of the preceding claims, wherein the inorganic filler is selected from calcium carbonate, magnesium carbonate, talc, aluminum trihydrate, vermiculite, antimony oxide, titanium dioxide, aluminum trihydrate, clay, or combinations thereof.

6. The aqueous composition according to any one of the preceding claims, wherein the dispersant is selected from polyphosphates, polycarboxylatees, poly(meth)acrylates, or citrates.

7. A coated nonwoven fiber felt, said coated nonwoven fiber felt comprising: (a) a precursor felt, said precursor felt comprising: • Including nonwoven fiber webs made of glass fiber, and • First adhesive; and (b) A hydrophobic coating applied to the precursor felt, wherein the hydrophobic coating is formed from an aqueous composition according to any one of the preceding claims.

8. The coated nonwoven fiber mat according to claim 7, wherein, when measured according to EN20535 applicable to nonwoven fiber mats, the coated nonwoven fiber mat has a content of less than 100 g / m³. 2 The Cobb value.

9. A method for manufacturing coated nonwoven fiber mat, the method comprising the following steps: (v) Providing a precursor mat comprising glass fiber and a first adhesive; (vi) Depositing the aqueous composition according to any one of claims 1 to 6 onto the precursor felt; (vii) The precursor felt is coated with the aqueous composition using a roller-lined scraper technique. When the precursor felt and the aqueous composition pass through a predetermined gap between the scraper and the roller... The scraper contacts the aqueous composition. The aqueous composition exhibits shear thinning upon contact with the scraper, and The precursor felt is coated with the aqueous composition; as well as (viii) Dry the coated precursor felt to form the coated nonwoven fiber felt.

10. The method of claim 9, wherein the precursor felt is prepared by a method comprising the following steps: (i) Provides an aqueous mixture comprising glass fiber and a first binder; (ii) forming a dispersion of the aqueous mixture; (iii) Depositing the aqueous dispersion to form a wet-laid fiber web of glass fibers and a first binder; (iv) Dry the wet-laid fiber web of the glass fiber and the first binder to form the precursor felt.

11. The method of claim 9, wherein the precursor felt is prepared by a method comprising the following steps: (i) Provide an aqueous mixture containing glass fibers; (ii) Depositing the aqueous mixture to form a wet-laid fiber web of glass fibers; (iii) Applying an aqueous solution or dispersion of the first binder to the wet-laid fiber web of the glass fiber to form a wet-laid fiber web of glass fiber and the first binder; (iv) Dry the wet-laid fiber web of the glass fiber and the first binder to form the precursor felt.

12. A building panel, the building panel comprising: A first surface and a second surface opposite to the first surface. A coated nonwoven fiber mat, the coated nonwoven fiber mat being adhered to the first surface, the second surface, or both the first surface and the second surface, and The coated nonwoven fiber felt is as described in claim 7 or claim 8.

13. The building panel according to claim 12, wherein the building panel further comprises an ink layer as the outermost layer of the first surface, the second surface, or both the first surface and the second surface of the building panel.

14. The building panel according to claim 12 or claim 13, wherein the building panel is selected from the group consisting of ceiling tiles, gypsum board, building panels, insulation panels and flooring, optionally gypsum board.

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