The present invention provides a mounting mat for mounting a pollution control element or monolith in a pollution control device, said mounting mat comprising a layer having a mixture of long and short fibers wherein said short fibers have a length of not more than about 13 mm and wherein said long fibers have a length of at least about 20 mm and wherein the amount of said short fibers is at least about 3% by weight based on the total weight of said mixture of long and short fibers.

The present invention provides a mounting mat for mounting a pollution control element or monolith in a pollution control device, said mounting mat comprising a layer having a mixture of long and short fibers wherein said short fibers have a length of not more than about 13 mm and wherein said long fibers have a length of at least about 20 mm and wherein the amount of said short fibers is at least about 3% by weight based on the total weight of said mixture of long and short fibers.

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 carrier material includes at least a first thermoplastic fiber layer and a second thermoplastic fiber layer. At least a part of the first thermoplastic fiber layer and/or the second thermoplastic fiber layer at at least one boundary of the carrier material is removed, to provide a first part of a form-fit connection. The carrier material can be used in bituminous roofing membranes, roofing underlayment sheets, carriers for filter media, primary backings for tufted carpets and (cushion) vinyl floor coverings.

A carrier material for vinyl floor covering, wherein the carrier material includes a nonwoven layer containing at least 50 wt. % of thermoplastic fibers and a scrim for eliminating wrinkles in the vinyl floor covering. The scrim includes weft yarns having a linear density of 28 tex or less. The carrier material prevents the formation of surface irregularities and printing errors in the vinyl floor covering.

Provided is a laminate composite material, comprising a cover layer and at least one fiber nonwoven layer, comprising mineral fibers or thermoplastic fibers and 1 to 45% by wt. of a thermoplastic binder composition to bond together the nonwoven web of fibers, a method for manufacturing the laminate composite material and an insulation product or panel comprising the same. The laminate composite material according to the invention has excellent surface aspect, good acoustic and thermal insulation properties, a good thermoforming and deep shaping performance, dimensional stability and sufficient stiffness at very low weights.

Provided is a laminate composite material, comprising a cover layer and at least one fiber nonwoven layer, comprising mineral fibers or thermoplastic fibers and 1 to 45% by wt. of a thermoplastic binder composition to bond together the nonwoven web of fibers, a method for manufacturing the laminate composite material and an insulation product or panel comprising the same. The laminate composite material according to the invention has excellent surface aspect, good acoustic and thermal insulation properties, a good thermoforming and deep shaping performance, dimensional stability and sufficient stiffness at very low weights.