This invention relates to a low fiber, plyable facer suitable for use in the construction industry, particularly for insulation board manufacture, comprising a dry preformed fiber mat containing a binder for the fibers, preferably a preformed glass mat, coated with a prefoamed composition which contains a thixotropic polymer latex, a foam sustaining amount of a surfactant and a flame retarding and/or strengthening amount of a mineral filler and also to the use and process for the preparation of the above as well as to a siding underlayment or insulation board having a foamed, thermosetting resin core which is surfaced with said facer as a product for commercial use.

This invention relates to a low fiber, plyable facer suitable for use in the construction industry, particularly for insulation board manufacture, comprising a dry preformed fiber mat containing a binder for the fibers, preferably a preformed glass mat, coated with a prefoamed composition which contains a thixotropic polymer latex, a foam sustaining amount of a surfactant and a flame retarding and/or strengthening amount of a mineral filler and also to the use and process for the preparation of the above as well as to a siding underlayment or insulation board having a foamed, thermosetting resin core which is surfaced with said facer as a product for commercial use.

A fiber glass mat containing a novolac resin having an acid solubility of at least about 35 wt. percent is especially useful for bonding to a light weight fibrous or foam web or board, such as a polymer fiber web. A method of making the mat by wet laying a slurry containing the fiber and the novolac resin particles and then further adding an aqueous solution or slurry containing a crosslinking agent for the novolac resin and a laminate containing the fiber glass mat are disclosed.

To provide a heat resistant filter of which the reduction of tensile strength and folding endurance is small even when used as a filter material for a filter used at high temperatures, failure of the filter material is difficult even when used at high temperatures, and which is capable of achieving a long life. The heat resistant filter contains: a heat resistant organic fiber base material, and a resin composition which contains an alkaline substance and which adheres to the heat resistant organic fiber base material.

This process and apparatus use at least one chopper unit. The fiber choppers may be laser beam choppers or existing standard chopper units. The process and apparatus for producing a fiber-reinforced molded composite comprises providing a moldable composition, sequentially spraying a moldable composition into the mold, subsequently providing chopped fibers to the moldable composition and depositing the moldable composition and chopped fibers in mold and molding the moldable composition and fibers in the apparatus under heat and pressure to form the molded composite. One industrial application for these choppers is compression molding of interior trim panels for automobile doors. The choppers spray chopped glass fiber strands into a resin mixture. The glass and a polyol, isocyanate (--NCO) urethane resin mixture at the proper glass loading, distribution and pattern is fed to the mold.