Glass fiber reinforced gypsum boards and methods of making them

Patent metadata

Field	Value
Publication number	US-2025243114-A1
Application number	US-202519042067-A
Country	US
Kind code	A1
Filing date	Jan 31, 2025
Priority date	Jan 31, 2024
Publication date	Jul 31, 2025
Grant date	—

Abstract

According to one embodiment, a gypsum-based slurry composition is disclosed. The gypsum-based slurry composition can include a precursor stucco component, a precursor reinforcement component comprising glass fibers coated with a glass fiber coating. The glass fiber coating can comprise PVOH, PVAC, hydrophilic silane, or a combination thereof.

First claim

What is claimed is:

1 . A gypsum-based slurry composition comprising:
a precursor stucco component, a precursor reinforcement component comprising glass fibers coated with a glass fiber coating, the glass fiber coating comprising PVOH, PVAC, hydrophilic silane, or a combination thereof.

2 . The gypsum-based slurry composition of claim 1 , wherein the glass fiber coating comprises a combination of PVOH and PVAC.

3 . The gypsum-based slurry composition of claim 1 , wherein the glass fiber coating comprises hydrophilic silane.

4 . The gypsum-based slurry composition of claim 1 , wherein the glass fiber coating comprises a coating slump factor S c of greater than 0.98 in and not greater than 1.5.

5 . The gypsum-based slurry composition of claim 1 , wherein the glass fiber coating comprises a coating contact angle factor C c of no greater than 54° and at least 40°.

6 . The gypsum-based slurry composition of claim 1 , wherein the gypsum-based slurry composition comprises a slurry slump factor S s of at least 9.3 in and not greater than 10 in.

7 . A gypsum-based construction material comprising a gypsum core, wherein the gypsum core comprises:
a gypsum component, a reinforcement component comprising glass fibers coated with a glass fiber coating, the glass fiber coating comprising PVOH, PVAC, hydrophilic silane, or a combination thereof.

8 . The gypsum-based construction material of claim 7 , wherein the glass fiber coating comprises a combination of PVOH and PVAC.

9 . The gypsum-based construction material of claim 7 , wherein the glass fiber coating comprises hydrophilic silane.

10 . The gypsum-based construction material of claim 7 , wherein the glass fiber coating comprises a coating slump factor S c of greater than 0.98 in and not greater than 1.5.

11 . The gypsum-based construction material of claim 7 , wherein the glass fiber coating comprises a coating contact angle factor C c of no greater than 54° and at least 40°.

12 . The gypsum-based construction material of claim 7 , wherein the gypsum-based slurry is casted to form a gypsum-based construction material, such as, a panel, a board, walls, plinths, slabs, columns, sheets, casts or shafts.

13 . The gypsum-based construction material of claim 7 , wherein the construction material has a flexural strength of at least 30.0 lbf and no greater than 100 lbf.

14 . The gypsum-based construction material of claim 7 , wherein the construction material has a density of at least 1250 lbs./msf and less than 3150 lbs./msf.

15 . A method of forming a gypsum-based construction material, wherein the method comprises
providing a gypsum-based slurry composition comprising: a precursor stucco component, a precursor reinforcement component comprising glass fibers coated with a glass fiber coating, the glass fiber coating comprising PVOH, PVAC, hydrophilic silane, or a combination thereof, depositing the slurry composition to form a gypsum preform of the gypsum-based construction material preform, and drying the gypsum prefrom of the gypsum-based construction material to form a gypsum core.

16 . The method of claim 15 , wherein the glass fiber coating comprises a combination of PVOH and PVAC.

17 . The method of claim 15 , wherein the glass fiber coating comprises hydrophilic silane.

18 . The method of claim 15 , wherein the glass fiber coating comprises a coating slump factor S c of greater than 0.98 in and not greater than 1.5.

19 . The method of claim 15 , wherein the glass fiber coating comprises a coating contact angle factor C c of no greater than 54° and at least 40°.

20 . The method of claim 15 , wherein the gypsum-based slurry composition comprises a slurry slump factor S s of at least 9.3 in and not greater than 10 in.

Assignees

• Certainteed Gypsum Inc

Inventors

• Amato Dahlia
• Lespiat Remi
• Ernoult Lea
• Jones Roger
• Adjoua Serge

Classifications

• B32B13/12

  of synthetic resin · CPC title

• B32B27/306

  comprising vinyl acetate or vinyl alcohol (co)polymers · CPC title

• B32B2607/00

  Walls, panels · CPC title

• B32B2250/03

  3 layers · CPC title

• B32B2250/40

  Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA · CPC title