MAT-FACED GYPSUM BOARD AND METHOD OF MAKING THEREOF
First Claim
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1. A method of forming a gypsum board, the method comprising:
- (a) providing a porous substrate having an inner surface;
(b) applying a particulate matter to the inner surface of the porous substrate forming a powder faced substrate;
(c) depositing an aqueous gypsum slurry to the inner surface of the powder faced substrate over at least a portion of the applied particulate matter forming a slurry coated substrate wherein the particulate matter fills a portion of the pores in the porous substrate to hinder penetration of the gypsum slurry therethrough; and
(d) forming the slurry coated substrate into the gypsum board.
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Abstract
A mat-faced gypsum board and method of making thereof is provided having a particulate matter applied on an inner surface of the facer mat and extending partially into the mat from the inner surface thereof. The particulate matter, which is preferably a hydratable powder such as calcium sulfate hemihydrate, minimizes and, preferably, prevents bleed through of a gypsum slurry during formation of the gypsum board.
119 Citations
33 Claims
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1. A method of forming a gypsum board, the method comprising:
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(a) providing a porous substrate having an inner surface; (b) applying a particulate matter to the inner surface of the porous substrate forming a powder faced substrate; (c) depositing an aqueous gypsum slurry to the inner surface of the powder faced substrate over at least a portion of the applied particulate matter forming a slurry coated substrate wherein the particulate matter fills a portion of the pores in the porous substrate to hinder penetration of the gypsum slurry therethrough; and (d) forming the slurry coated substrate into the gypsum board. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A mat-faced gypsum board comprising:
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(a) a gypsum-based core; (b) a fibrous mat having an inner surface facing at least one side of the gypsum-based core; and (c) a hydrated particulate material on the inner surface of the fibrous mat and extending partially into the fibrous mat from the inner surface thereof; wherein the hydrated particulate material is supplied independent of the gypsum-based core. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23)
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24. A mat-faced gypsum board comprising:
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(a) a gypsum-based core; (b) a fibrous mat having an inner surface facing at least one side of the gypsum-based core; and (c) a hydrated particulate material on the inner surface of the fibrous mat and extending partially into the fibrous mat from the inner surface thereof; wherein the composition of the hydrated particulate material differs from the composition of the gypsum-based core. - View Dependent Claims (25, 26, 27, 28, 29, 30, 31, 32, 33)
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Specification