Method of making coated mat online and coated mat products

Abstract From the Canadian patent

New coated nonwoven fibrous mats having properties particularly suited for a facer on gypsum wallboard and other substrates and in laminates of various types and the method of making the coated mat is disclosed. The mat preferably contains a major portion of glass fibers and a minor portion of a resinous binder. The coating is preferably permeable and reduces fiber dust and abrasion experienced in the past with relatively coarse relatively inexpensive glass fibers in the mat. Contrary to previous coating methods the coated fibrous mat is made in-line on a wet mat forming production line by applying a wet foam binder onto a wet fibrous web followed by drying and curing in-line.