Gypsum board and systems containing same

• US 5,644,880 A
• Filed: 06/07/1995
• Issued: 07/08/1997
• Est. Priority Date: 02/27/1984
• Status: Expired due to Fees

• Current Assignee: Georgia-Pacific Gypsum LLC
• Original Assignee: Georgia-Pacific Corporation
• Inventors: Randall, Brian G., Lehnert, Charles W.
• Primary Examiner(s): Friedman, Carl D.
• Assistant Examiner(s): WILKENS, KEVIN DOUGLAS
• Application Number:
  US08/480,800
• Time in Patent Office: 762 Days
• Field of Search: 52/309.1, 52/309.17, 52/408, 52/481.1, 52/783.1, 52/794.1, 52/796.1
• US Class Current: 52/408
• 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 13/14 next to a fibrous or filamentary layer
• CPC Class Codes: E04C 2/043 of plaster E04C2/049 takes precedence
• CPC Class Codes: E04C 2/284 at least one of the materials being insulating
• CPC Class Codes: E04C 2/288 composed of insulating material and concrete, stone or stone-like material
• 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: E04D 13/1643 the roof structure being formed by load bearing corrugated sheets, e.g. profiled sheet metal roofs
• CPC Class Codes: E04D 13/1668 the insulating material being masses or granules applied in situ
• CPC Class Codes: E04F 13/047 Plaster carrying meshes

Abstract

Finishing systems and roof decks are provided which include a gypsum board having a set gypsum core faced with a fibrous mat. The gypsum core includes one or more additives which are effective in simultaneously improving the water and fire resistance of the board. In preferred embodiments, the board has sufficient water-resistant additive for absorbing less than about 10% water in an ASTM C-473 test.

Claims

1. A gypsum board comprising set gypsum-containing core and at least one sheet of porous mat comprising randomly distributed non-woven, chopped glass strand fibers bonded by adhesive, said fibers consisting essentially of fibers selected from the group consisting of miner fibers, synthetic resin fibers, and combinations of these, said mat being adhered to said set gypsum core by a portion of said set gypsum being mechanically interlocked with at least a portion of said fibers, said mat having an outer surface which is substantially free of set gypsum from said core.

2. The gypsum board of claim 1 further comprising a second porous mat on the side of said core opposite said first porous mat and adhered to said opposite side of said gypsum core by a portion of said set gypsum from said core.

3. The gypsum board of claim 1 wherein said set gypsum core includes a water-resistant additive which imparts to said board sufficient water-resistance such that said core absorbs less than 5% of its weight in water when said board is tested in accordance with ASTM method C-473.

4. An exterior insulation finishing system comprising the gypsum board of claim 1.

5. A roof deck system comprising the gypsum board of claim 1.

6. The roof deck system of claim 5 comprising support means, said gypsum board overlying said support means, and an exterior finishing material overlying said gypsum board.

7. An exterior insulation system for a building, comprising a support surface, insulating material having an inner surface and an outer surface, the inner surface of which is adhered to the support surface by an adhesive material and an exterior finishing material overlying the outer surface of the insulating material, said support surface comprising a gypsum board according to claim 1.

8. The exterior insulation system of claim 7 wherein said insulating material is substantially free of channels penetrating therethrough and between the inner and outer surfaces.