The present invention relates to a method of manufacturing a non-synthetic textile surface structure, and to the non-synthetic textile surface structure itself.

According to one embodiment, a method of forming a facer includes forming a first layer of nonwoven glass fibers and positioning a second layer of reinforcement fibers atop the first layer of nonwoven glass fibers. The method also includes coating the first layer of nonwoven glass fibers and/or the second layer of reinforcement fibers with a binder composition and pressing the first layer of nonwoven glass fibers and the second layer of reinforcement fibers together between a pair of rollers. The binder composition is then dried to couple the first layer of nonwoven glass fibers and the second layer of reinforcement fibers to form the facer. The first layer of nonwoven glass fibers and/or the second layer of reinforcement fibers are free of a material coating prior to coating of the binder composition.

According to one embodiment, a method of forming a facer includes forming a first layer of nonwoven glass fibers and positioning a second layer of reinforcement fibers atop the first layer of nonwoven glass fibers. The method also includes coating the first layer of nonwoven glass fibers and/or the second layer of reinforcement fibers with a binder composition and pressing the first layer of nonwoven glass fibers and the second layer of reinforcement fibers together between a pair of rollers. The binder composition is then dried to couple the first layer of nonwoven glass fibers and the second layer of reinforcement fibers to form the facer. The first layer of nonwoven glass fibers and/or the second layer of reinforcement fibers are free of a material coating prior to coating of the binder composition.

A filtration media with improved filtration, strength, tear resistance and air permeability in the form of a relatively thin and lightweight wet-laid fibrous web that has a wet Mullen ratio of 60% to 80% to ensure that the media is flexible enough to be formed into a fluted structure, and strong enough to retain the fluted structure when wound into a roll and to permit further processing without the media becoming too brittle. The filtration media comprises a blend of cellulose and synthetic fibers having a weight percent of 81 wt % to 87 wt % of a weight of the media and a resin binder having a weight of 13 wt % to 19 wt % (preferably about 16 wt %) of the weight of the media.

An article including one or more foam material layers and one or more nonwoven fibrous layers. The article is adapted to be used as insulation within a wall or hollow cavity. The article is a material that is acoustically and thermally functional, thermally insulative, easy to handle and fabricate, easy to slide into wall channels or place into wall, light weight, non-shedding, non-toxic, no mold/mildew, continuous (longer lengths in one piece), resistant to tearing/breaking, that has a high R-value, or a combination thereof.

An article including one or more foam material layers and one or more nonwoven fibrous layers. The article is adapted to be used as insulation within a wall or hollow cavity. The article is a material that is acoustically and thermally functional, thermally insulative, easy to handle and fabricate, easy to slide into wall channels or place into wall, light weight, non-shedding, non-toxic, no mold/mildew, continuous (longer lengths in one piece), resistant to tearing/breaking, that has a high R-value, or a combination thereof.

A decorative, nonwoven laminate and a method of forming, including a first side of a first nonwoven affixed to one or both of a) a first side of a polymeric sheet or b) a second nonwoven, wherein the first nonwoven exhibits a basis weight of 15 g/m.sup.2 to 500 g/m.sup.2 and the second nonwoven exhibits a basis weight of 15 g/m.sup.2 to 1200 g/m.sup.2; and a colorant deposited on a second side of the first nonwoven. A topical coating may or may not be applied to improve durability of the printed surface layer.

A decorative, nonwoven laminate and a method of forming, including a first side of a first nonwoven affixed to one or both of a) a first side of a polymeric sheet or b) a second nonwoven, wherein the first nonwoven exhibits a basis weight of 15 g/m.sup.2 to 500 g/m.sup.2 and the second nonwoven exhibits a basis weight of 15 g/m.sup.2 to 1200 g/m.sup.2; and a colorant deposited on a second side of the first nonwoven. A topical coating may or may not be applied to improve durability of the printed surface layer.

Fibrous structures, for example pre-moistened fibrous structures, having a novel contact surface (micro protrusion surface) and methods for using the fibrous structures and making the fibrous structures are provided.

A liquid binder composition for binding fibrous materials in the fabrication of resin-infusible preform is disclosed. The binder composition is an aqueous dispersion containing (a) one or more multifunctional epoxy resins, (b) at least one thermoplastic polymer, (c) one or more surfactants selected from anionic surfactants, nonionic surfactants, and combinations thereof, (d) water, and is essentially free of organic solvents. Also disclosed is an emulsification process for producing the liquid binder composition.