Coated nonwoven mat with tuned performance properties
AssigneeOwens Corning Intellectual Capital, LLC
InventorsJianhui Wu, Allegra Flohr, Merideth Cooper-Steiger, Daryl Wernette
Life of this patent
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Abstract
A coated nonwoven mat includes a nonwoven base layer and a coating layer. The nonwoven base layer is formed from a plurality of fibers held together by a binder and includes a first surface and a second surface. The coating layer includes a coating composition comprising a binder component, a filler, and one or more performance modifiers. The coated nonwoven mat has an average Gurley porosity of at least 10 seconds and an average hydrostatic head performance of at least 10 mbar.
Claims22
A coated nonwoven mat comprising:
- a nonwoven base layer formed from a plurality of fibers held together by a binder, the nonwoven base layer having a first surface and a second surface;
- and
- a coating layer adhered to the first surface and extending partially into the nonwoven base layer, wherein the coating layer comprises a coating composition, wherein the coating composition comprises:
- a binder component in an amount from 2% to 20% by weight,
- a filler in an amount from 65% to 99% by weight, and
- at least one performance modifier in an amount from 0.05% to about 5.0% by weight, wherein the performance modifier comprises a hydrophobic additive.
- wherein the coated nonwoven mat has an average Gurley porosity of at least 10 seconds, and
- wherein the coated nonwoven mat has an average hydrostatic head performance of at least 10 mbar.
A method of making a coated nonwoven mat, the method comprising:
- providing a nonwoven base layer formed from a plurality of fibers held together by a binder, the nonwoven base layer having a first surface and a second surface;
- applying a coating composition to the first surface of the nonwoven base layer to form a coating layer on the nonwoven base layer, wherein the composition comprises:
- a binder component in an amount from 2% to 20% by weight,
- a filler in an amount from 65% to 99% by weight, and
- one or more performance modifiers in an amount from 0.05% to about 5.0% by weight, wherein the performance modifier comprises a hydrophobic additive, and heating the nonwoven base layer with the coating layer to form the coated nonwoven mat,
- wherein the coated nonwoven mat has an average Gurley porosity of at least 10 seconds, and
- wherein the coated nonwoven mat has an average hydrostatic head performance of at least 10 mbar.
A nonwoven mat comprising:
- a nonwoven base layer formed from a plurality of fibers held together by a binder, the nonwoven base layer having a first surface and a second surface;
- and
- a coating composition applied to the second surface and extending at least partially into a thickness of the nonwoven base layer, wherein the coating composition comprises:
- a binder component in an amount from 2% to 20% by weight,
- a filler in an amount from 65% to 99% by weight, and
- at least one performance modifier in an amount from 0.05% to about 5.0% by weight, wherein the performance modifier comprises a hydrophobic additive,
- wherein the nonwoven mat has an average Gurley porosity of at least 10 seconds, and
- wherein the nonwoven mat has an average hydrostatic head performance of at least 10 mbar.
Dependencies are inferred from the claim text.