Continuous filament mat and method of making

A continuous filament mat having a tensile strength in the machine direction (MD) and in the cross machine direction (CM), wherein the MD tensile strength is at least 70% of the CM tensile strength.

A method of manufacturing a continuous filament mat comprising the steps of:

• drawing plurality of groups of fibers from a plurality of fiber sources, and depositing a plurality of fiber groups in a predetermined fiber lay down pattern on a forming conveyor.

The method of manufacture of claim26, wherein said material property is selected from the group consisting of mat density, MD weight variation, CM weight variation, MD tensile strength and CM tensile strength.

The continuous filament mat of claim A23, wherein the continuous filament mat is formed of fibers selected from the group consisting of mineral fibers, glass fibers, carbon fibers, basalt fibers, polymer fibers, nylon fibers, polyester fibers, polyamide fibers, aramid fibers, PVC fibers, PVAC fibers, melamine fibers, acrylic fibers, visil fibers, natural fibers, staple fibers, chopped fibers and mixtures thereof.

A method of manufacturing a continuous filament mat comprising the steps of:

• drawing plurality of groups of fibers from a plurality of fiber sources, and depositing a plurality of fiber groups in a predetermined fiber lay down pattern on a forming conveyor, said fiber lay down pattern including pattern having a predetermined period, frequency and interval.

The method of manufacture of claim 35, further comprising the step of:

• measuring a material property of the continuous filament mat and altering said predetermined pattern in order to alter said material property.