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.