Glass mat with reinforcing binder

• US 4,879,173 A
• Filed: 01/06/1988
• Issued: 11/07/1989
• Est. Priority Date: 01/06/1988
• Status: Expired due to Term

• Current Assignee: Georgia-Pacific Gypsum LLC
• Original Assignee: Georgia-Pacific Corporation
• Inventors: Randall, Brian G.
• Primary Examiner(s): Bell, James J.
• Application Number:
  US07/141,998
• Time in Patent Office: 671 Days
• Field of Search: 428/284, 428/285, 428/298, 428/703, 428/913, 428/286, 428/290, 428/288, 428/198
• US Class Current: 442/86
• CPC Class Codes: B28B 11/04 for coating or applying engobing layersglazing, engobing C04B
• CPC Class Codes: B28B 19/0092 to webs, sheets or the like, e.g. of paper, cardboard
• CPC Class Codes: B28B 23/0006 the reinforcement consisting of aligned, non-metal reinforcing elements
• CPC Class Codes: B32B 11/02 with fibres or particles being present as additives in the layer
• CPC Class Codes: B32B 13/12 of synthetic resin
• CPC Class Codes: B32B 13/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2305/026 Porous
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2315/02 Ceramics
• CPC Class Codes: B32B 2419/06 Roofs, roof membranes
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04B 9/045 being laminated
• CPC Class Codes: E04C 2/043 of plaster E04C2/049 takes precedence
• CPC Class Codes: E04D 11/02 Build-up roofs, i.e. consisting of two or more layers bonded together in situ, at least one of the layers being of watertight composition gravelling of flat roofs E04D7/00; venting or ventilation E04D13/17
• CPC Class Codes: E04F 13/047 Plaster carrying meshes
• CPC Class Codes: E04F 13/141 with an outer layer of concrete E04F13/147 takes precedence
• CPC Class Codes: Y10T 428/24595 and varying density
• CPC Class Codes: Y10T 428/249932 : Fiber embedded in a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
• CPC Class Codes: Y10T 428/249939 : Two or more layers
• CPC Class Codes: Y10T 428/24994 : Fiber embedded in or on the surface of a polymeric matrix
• CPC Class Codes: Y10T 428/24995 : Two or more layers
• CPC Class Codes: Y10T 428/249952 : At least one thermosetting synthetic polymeric material layer
• CPC Class Codes: Y10T 442/2098 : At least two coatings or impregnations of different chemical composition
• CPC Class Codes: Y10T 442/2221 : Coating or impregnation is specified as water proof
• CPC Class Codes: Y10T 442/2992 : Coated or impregnated glass fiber fabric

Abstract

In gypsum board faced with a fibrous mat, for example, a mat of glass filaments adhesively bound together, improvements are realized by the use of a reinforcing resinous binder in the mat.

Claims

1. A fibrous mat having a predetermined thickness and property and comprising fibers bound together with and adhesive and including also a reinforcing resinous binder on the surface of the mat and extending but partway through the thickness of the mat into the interstices thereof, so that said mat porosity is not significantly changed, the amount of reinforcing resinous binder being about 3 to about 40 g/square meter of mat.

2. A mat according to claim 1 wherein the amount of binder is no greater than about 25 g/square meter of mat.

3. A mat according to claim 1 wherein the amount of binder is about 5 to about 15 g/square meter of mat.

4. Gypsum board comprising a set gypsum core having at least one of its surfaces faced with a fibrous mat according to claim 1, the mat being adhered to the core by set gypsum of the core which penetrates but partway through the thickness of the mat.

8. Gypsum board according to claim 4, 5, 6, or 7 wherein aid mat comprises fiber glass filaments oriented in random pattern and bound together with a resin binder.

9. Gypsum board according to claim 8 wherein said reinforcing resinous binder is a styrene-acrylic copolymer.

10. Gypsum board according to claim 8 wherein said reinforcing resinous binder is a self-crosslinking vinyl acetate-acrylic copolymer.

11. A built-up-roof including a support member comprising the gypsum board of claim 4 or 5 and adhered thereto a continuous film of hydrocarbon water-proofing material formed by the solidification of a hot liquid form of the material.

5. Gypsum board comprising a set gypsum core having adhered to at least one of its surfaces a non-woven glass fiber mat having a predetermined thickness and porosity and comprising glass fibers bound together by an adhesive and including also a reinforcing resinous binder on the surface of the mat and extending but partway through the thickness of the mat into the interstices thereof, so that said predetermined mat porosity is not significantly changed, the amount of the binder being such that the drying characteristics of the board are substantially the same as board comprising said mat without said binder.

6. Gypsum, board according to claim 5 wherein the amount of binder is at Least about 3 g/square meter of mat.

7. Gypsum board according to claim 6 wherein the amount of binder is about 5 to about 15 g/square meter of mat.