Gypsum products with improved glass fiber mat

Patent metadata

Field	Value
Publication number	US-9840843-B2
Application number	US-201414451817-A
Country	US
Kind code	B2
Filing date	Aug 5, 2014
Priority date	Aug 5, 2014
Publication date	Dec 12, 2017
Grant date	Dec 12, 2017

Abstract

A gypsum product with improved elasticity and increased nail-pull strength is provided, the product made with a glass fiber mat in which glass fibers are cross-linked with a polymeric resin. Further embodiments provide methods for making the glass fiber mats and gypsum products.

First claim

What is claimed is:

1. A method for improving elasticity and surface finish in a gypsum product, the method comprising: mechanically pre-pressing an untreated glass fiber mat; treating the pre-pressed untreated glass fiber mat with an acrylic resin to form a treated glass fiber mat; optionally post-pressing the treated glass fiber mat; and preparing a gypsum slurry and disposing the slurry on the pre-pressed treated glass fiber mat, and thereby forming a gypsum product.

2. The method of claim 1 , wherein the acrylic resin is an acrylo-polyester aqueous solution.

3. The method of claim 1 , wherein glass fibers in the glass fiber mat are randomly oriented.

4. The method of claim 1 , wherein the acrylic resin is used at about 10 lbs/MSF of the glass fiber mat.

5. The method of claim 1 , wherein the step of treating the pre-pressed untreated glass fiber mat with the acrylic resin comprises: soaking the pre-pressed untreated glass fiber mat in an aqueous acrylic resin solution, and causing glass fibers in the pre-pressed untreated glass fiber mat to cross-link by curing the acrylic resin.

6. The method of claim 5 , wherein the curing of the acrylic resin is accomplished by exposing the pre-pressed treated glass fiber mat to a temperature in the range from 2000 F to 5000 F.

7. The method of claim 1 , wherein the acrylic resin is selected from the group consisting of a polyacrylate, acrylo-polyester and acrylo-polystyrene.

8. The method of claim 1 , wherein the acrylic resin is an acrylo-polyester solution with 50% solids.

9. The method of claim 5 , wherein at least one of the steps of soaking and curing takes place after the gypsum product has been formed.

Assignees

• United States Gypsum Co

Inventors

• Li Alfred
• Xu Wei
• Scalf Mark B
• Song David

Classifications

• B32B2250/40

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

• B32B2260/023

  Two or more layers · CPC title

• B32B2262/101

  Glass fibres · CPC title

• B32B2315/00

  Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04 · CPC title

• B32B37/24

  with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate (B32B37/15 takes precedence) · CPC title