Mat-faced board

Patent metadata

Field	Value
Publication number	US-10207475-B2
Application number	US-201715484818-A
Country	US
Kind code	B2
Filing date	Apr 11, 2017
Priority date	May 13, 2016
Publication date	Feb 19, 2019
Grant date	Feb 19, 2019

Abstract

Disclosed is an improved facer mat for use as a cover sheet for gypsum board. Also disclosed are gypsum boards containing such mat facers on one or both major surfaces of the board (face and back sides when installed), a method of manufacturing such board, and a method of making the mat. The mat can comprise glass, thermoplastic, and/or thermoset fiber. In preferred embodiments, binder is included with the fiber. The mat has outer and inner surfaces. The mat comprises a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first substantial thickness, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second substantial thickness. The first region has (a) more hydrophilicity than the second region, (b) more wettability than the second region, and/or (c) less density than the second region.

First claim

The invention claimed is:

1. A gypsum board comprising:
(a) a gypsum core comprising a crystalline matrix of set gypsum, the core having a face surface and a back surface;
(b) a first mat having an outer surface and an inner surface, the first mat facing the face surface of the core, the first mat comprising a first region adjacent to the outer surface defined along a horizontal plane of the mat, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, wherein the first region is more hydrophilic than the second region; and optionally
(c) a second mat having an outer surface and an inner surface, the second mat facing the back surface of the core, the second mat comprising a third region adjacent to the outer surface of the second mat defined along a horizontal plane of the mat, and a fourth region adjacent to the inner surface defined along a horizontal plane of the mat, wherein the third region is more hydrophilic than the fourth region;
the first region exhibiting a lower contact angle when contacted with a coating material than the second region upon contact with the same coating material.

2. The gypsum board of claim 1 , wherein the first region is more wettable than the second region.

3. The gypsum board of claim 2 , wherein the first region is less dense than the second region.

4. The gypsum board of claim 1 , wherein the first region is less dense than the second region.

5. The gypsum board of claim 2 , wherein at least one mat contains a coating on the outer surface, the mat having a total thickness, and the coating when dried penetrates from about 20% to about 80% of the total mat thickness.

6. The gypsum board of claim 1 , wherein at least one of the mats is a bi-layer with one layer containing the first region and another layer containing the second region.

7. The gypsum board of claim 1 , wherein at least one of the mats is a tri-layer containing the first region in a first layer, the second region in a second layer, and a transition zone in a third layer.

8. The gypsum board of claim 1 , wherein the second mat is present.

9. A gypsum board comprising:
(a) a gypsum core comprising a crystalline matrix of set gypsum, the core having a face surface and a back surface;
(b) a first mat having an outer surface and an inner surface, the first mat facing the face surface of the core, the first mat comprising a first region adjacent to the outer surface defined along a horizontal plane of the mat, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, wherein the first region is more wettable than the second region; and optionally
(c) a second mat having an outer surface and an inner surface, the second mat facing the back surface of the core, the second mat comprising a third region adjacent to the outer surface of the second mat defined along a horizontal plane of the mat, and a fourth region adjacent to the inner surface defined along a horizontal plane of the mat, wherein the third region is more wettable than the fourth region;
the first region exhibiting a contact angle of about 60° or less when contacted with a coating material, and the second region exhibiting a contact angle of about 60° or greater when contacted with the same coating material, the first region exhibiting a lower contact angle than the second region.

10. The gypsum board of claim 9 , wherein the first region is less dense than the second region.

11. The gypsum board of claim 9 , wherein at least one mat contains a coating on the outer surface, the mat having a total thickness, and the coating when dried penetrates from about 20% to about 80% of the total mat thickness.

12. The gypsum board of claim 9 , wherein at least one of the mats is a bi-layer with one layer containing the first region and another layer containing the second region.

13. The gypsum board of claim 9 , wherein at least one of the mats is a tri-layer containing the first region in a first layer, the second region in a second layer, and a transition zone in a third layer.

14. The gypsum board of claim 9 , wherein the second mat is present.

15. A gypsum board comprising:
(a) a gypsum core comprising a crystalline matrix of set gypsum, the core having a face surface and a back surface;
(b) a first mat having an outer surface and an inner surface, the first mat facing the face surface of the core, the first mat comprising a first region adjacent to the outer surface defined along a horizontal plane of the mat, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, wherein the first region is less dense than the second region, and optionally
(c) a second mat having an outer surface and an inner surface, the second mat facing the back surface of the core, the second mat comprising a third region adjacent to the outer surface of the second mat defined along a horizontal plane of the mat, and a fourth region adjacent to the inner surface defined along a horizontal plane of the mat, wherein the third region is less dense than the fourth region;
the first region of at least one of the mats exhibiting a lower contact angle when contacted with a coating material than the second region upon contact with the same coating material.

16. The gypsum board of claim 15 , wherein at least one of the mats contains a coating applied to the outer surface.

17. The gypsum board of claim 16 , wherein at least one of the mats has a total thickness, and the coating when dried penetrates from about 20% to about 80% of the total mat thickness.

18. The gypsum board of claim 15 , wherein at least one of the mats is a bi-layer with one layer containing the first region and another layer containing the second region.

19. The gypsum board of claim 15 , wherein at least one of the mats is a tri-layer containing the first region in a first layer, the second region in a second layer, and a transition zone in a third layer.

20. The gypsum board of claim 15 , wherein the second mat is present.

Assignees

• United States Gypsum Co

Inventors

• Shake Michael Patrick
• Blackburn David R
• Donelan Jeffrey

Classifications

• B32B2419/00

  Buildings or parts thereof · CPC title

• B32B2307/73

  Hydrophobic · CPC title

• B32B2307/728

  Hydrophilic · CPC title

• B32B2307/70

  Other properties · CPC title

• B32B2266/049

  Water-setting material, e.g. concrete, plaster or asbestos cement · CPC title