The background art contains several examples of methods for constructing fibrous mats. An example is disclosed in U.S. Pat. No. 5,565,049 to Simmons, et al. Simmons discloses a method of making mats from chopped fibrous material. The method uses an elongated endless transport belt that extends over a pair of rollers. At an initial station, a series of spools deliver continuous fiber strands into a cutting station. The cut strands are deposited onto the belt to form a loose fibrous mat structure. The mat structure is then transported to a misting station where nozzles spray a fine mist of water onto the mat structure. An adhesive powder is then applied uniformly over the top surface of the mat structure. The powdered adhesive takes the form of granules that are metered out of an adhesive applicator. At a subsequent heating station an upper belt is provided that applies pressure to the mat. The heating station also includes heating elements positioned above and below the mat structure. The pressure and heat cause the mat structure to flatten out and the adhesive to become plasticized. Next, a cooling station is provided that brings the temperature of the mat down below the initial plasticizing temperature of the adhesive. This causes the adhesive to re-solidify and bind the fibers together.
Another method of making fibrous mats is disclosed in U.S. Pat. No. 5,051,122 to Reese et al. Reese discloses a method of making mats of continuous glass fiber strands in which a heated calendaring roll and continuous belt are used to compact the mat. A plurality of strand feeders are traversed across the surface of a moving perforated conveyor with each feeder drawing at least one continuous strand from a supply source and projecting it onto the surface of the conveyor belt to form a loose fibrous mat structure. Powdered resin particles are distributed over the loose mat, which is then passed between a second moving conveyor or belt and at least one heated calendaring roller. One embodiment uses water to wet the mat for easier distribution of the resinous material. As the mat passes to a second conveyor belt it is pinched between the surfaces of the conveyor and a separately driven, rotating, heated calendar roll. As the mat passes around the circumference of the roll it is compacted against it by the tension of the belt. As the belt turns, it separates the compacted mat from the calendar roll and continues its path. Steam from the heating of the mat by the calendar roll is vented away by means of a hood.
Although each of the above references discloses a useful construction method, the references also suffer from certain disadvantages. For instance, each of the references applies a resin or adhesive in a particulate or granular form. This application technique requires multiple steps and does not adequately coat the underlying fibers. As a result there is insufficient bonding between adjacent fibers. The background art likewise fails to illustrate a method for constructing fibrous mats in conjunction with composite building boards. The system and method of the present disclosure are aimed at overcoming these and other shortcomings in the background art.