Patent ID: 11951712
Assignee: JOHNS MANVILLE
Field: Surface technology, coating (Chemistry)
Classification: CPC B  E | IPC B  E

Claim 0:
1. A method of forming a multi-layer fiber mat comprising:
pouring or discharging a first fluid mixture into a hydroformer and onto a porous belt or surface, the first fluid mixture comprising a first fluid and a first group of fibers that are homogenously mixed or dispersed within the first fluid;
draining or removing the first fluid from the first fluid mixture as the first fluid mixture is poured or discharged onto the porous belt or surface in order to form a layer of the first group of fibers atop the porous belt or surface;
pouring or discharging a second fluid mixture into the hydroformer and onto the porous belt or surface atop the layer of the first group of fibers as the first fluid is drained or removed from the first fluid mixture, the second fluid mixture comprising a second fluid and a second group of fibers that are homogenously mixed or dispersed within the second fluid;
draining or removing the second fluid from the second fluid mixture as the second fluid mixture is poured or discharged onto the porous belt or surface in order to form a layer of the second group of fibers atop the porous belt or surface and atop the layer of the first group of fibers, wherein the layer of the second group of fibers and the layer of the first group of fibers are simultaneously formed; and
applying a binder to the layer of the first group of fibers and the layer of the second group of fibers in order to simultaneously bind the layer of the first group of fibers and the layer of the second group of fibers together and bind the first group of fibers and the second group of fibers together;
wherein an entire volume of the second fluid mixture is poured or discharged into the hydroformer in direct fluid contact with the first fluid mixture such that the first fluid mixture and the second fluid mixture are simultaneously poured onto the porous belt or surface.