Gypsum board faced with non-woven glass fiber mat

Abstract

A gypsum board comprises a set gypsum layer having a first face and a second face. A fibrous mat is affixed to at least one of the faces. The mat comprises a non-woven web bonded together with a resinous binder. The web is composed of chopped continuous glass fibers having an average fiber diameter ranging from about 9.5 to 12.5 μm. The board is exceedingly durable. It has a smooth surface that is readily finished in an aesthetically pleasing way, using paint or other wall covering systems.

What is claimed is:  
     
         1 . A gypsum board, comprising: 
 a. a gypsum layer having a first face and a second face and comprising set gypsum; and    b. first and second facers affixed to said first and second faces, said first facer being a fibrous mat comprising a non-woven web bonded together with a resinous binder, and said web being composed of chopped continuous glass fibers having an average fiber diameter ranging from about 9.5 to 12.5 μm.    
     
     
         2 . A gypsum board as recited by  claim 1 , wherein said chopped continuous glass fibers are composed of at least one member selected from the group consisting of E glass, C glass, T glass, sodium borosilicate glass, and mixtures thereof.  
     
     
         3 . A gypsum board as recited by  claim 1 , wherein said chopped continuous glass fibers are composed of E glass.  
     
     
         4 . A gypsum board as recited by  claim 1 , wherein at least about 90% by weight of said chopped continuous glass fibers have a diameter ranging between about 9.5 and 12.5 μm.  
     
     
         5 . A gypsum board as recited by  claim 1 , wherein at least about 95% by weight of said chopped continuous glass fibers have a diameter ranging between about 9.5 and 12.5 μm.  
     
     
         6 . A gypsum board as recited by  claim 1 , wherein at least about 97% by weight of said chopped continuous glass fibers have a diameter ranging between about 9.5 and 12.5 μm.  
     
     
         7 . A gypsum board as recited by  claim 1 , wherein said chopped continuous glass fibers have an average fiber length ranging from about 6 to 12 mm.  
     
     
         8 . A gypsum board as recited by  claim 1 , wherein at least a majority of said chopped continuous glass fibers have a fiber length ranging from about 6 to 18 mm.  
     
     
         9 . A gypsum board as recited by  claim 1 , wherein said resinous binder is composed of at least one member selected from the group consisting of urea formaldehyde; conventional modified urea formaldehyde; acrylic resin; melamine resin; high nitrogen melamine resin; homopolymer and copolymer of polyacrylic acid having a molecular weight of less than 10,000; crosslinking acrylic copolymer; crosslinked vinyl chloride acrylate copolymer; and modified acrylic latex binder.  
     
     
         10 . A gypsum board as recited by  claim 1 , wherein said resinous binder is composed of a modified acrylic latex binder.  
     
     
         11 . A gypsum board as recited by  claim 9 , wherein said resinous binder further comprises a cross-linker in an amount ranging up to about 10 weight percent.  
     
     
         12 . A gypsum board as recited by  claim 11 , wherein said cross linker is present in an amount ranging from about 2 to 5 weight percent.  
     
     
         13 . A gypsum board as recited by  claim 11 , wherein said resinous binder comprises melamine formaldehyde.  
     
     
         14 . A gypsum board as recited by  claim 1 , wherein said resinous binder has a glass transition temperature ranging from about 15 to 45° C.  
     
     
         15 . A gypsum board as recited by  claim 1 , wherein said resinous binder further comprises at least one water repellant agent.  
     
     
         16 . A gypsum board as recited by  claim 1 , wherein said fibrous mat further comprises effective amounts of fine particles of limestone, glass, clay, coloring pigments, biocide, fungicide, intumescent material, or mixtures thereof.  
     
     
         17 . A gypsum board as recited by  claim 1 , wherein said fibrous mat has a basis weight ranging from about 0.6 to 2.2 pounds per 100 square feet.  
     
     
         18 . A gypsum board as recited by  claim 17 , wherein said fibrous mat has a basis weight ranging from about 0.9 to 2.2 pounds per 100 square feet.  
     
     
         19 . A gypsum board as recited by  claim 18 , wherein said fibrous mat has a basis weight of about 1.25±0.2 pounds per 100 square feet.  
     
     
         20 . A gypsum board as recited by  claim 1 , said second facer comprising kraft paper.  
     
     
         21 . A gypsum board as recited by  claim 1 , said second facer comprising a fibrous mat.  
     
     
         22 . A gypsum board as recited by  claim 1 , said second facer being a fibrous mat comprising a non-woven web bonded together with a resinous binder, and said web being composed of chopped continuous glass fibers having an average fiber diameter ranging from about 9.5 to 12.5 μm.  
     
     
         23 . A gypsum board as recited by  claim 1 , wherein said gypsum core further comprises at least one water repellant agent.  
     
     
         24 . A gypsum board as recited by  claim 1 , wherein said gypsum core further comprises reinforcing fiber.  
     
     
         25 . A gypsum board as recited by  claim 1 , wherein said gypsum core further comprises a biocide.  
     
     
         26 . A gypsum board as recited by  claim 1 , said board having flame resistance sufficient to pass the test of ASTM Method E84, Class 1.  
     
     
         27 . In a gypsum board having a first face and a second face and a non-woven fibrous mat affixed to at least one of said faces, the improvement wherein said mat comprises a web bonded together with a resinous binder and comprising chopped continuous glass fibers having an average fiber diameter ranging from about 9.5 to 12.5 μm.  
     
     
         28 . A process for manufacturing an article comprising a hydraulic set material layer having first and second faces, and first and second facers affixed thereto, at least said first facer comprising a non-woven, fibrous mat, the process comprising: 
 a. providing said non-woven, fibrous mat having a fibrous web composed of chopped continuous glass fibers having an average fiber diameter ranging from about 9.5 to 12.5 μm bound together with a resinous binder;    b. forming an aqueous slurry comprising at least one member selected from the group consisting of anhydrous calcium sulfate, calcium sulfate hemi-hydrate, and hydraulic setting cement;    c. distributing the slurry to form a layer on said first facer;    d. applying said second facer onto the top of said layer;    e. separating the resultant laminate into individual articles; and    f. drying the articles.    
     
     
         29 . A fibrous mat comprising a non-woven web bonded together with a resinous binder, said web being composed of chopped continuous glass fibers having an average fiber diameter ranging from about 9.5 to 12.5 μm.  
     
     
         30 . A fibrous mat as recited by  claim 29 , wherein at least about 90% by weight of said chopped continuous glass fibers have a diameter ranging between about 9.5 and 12.5 μm.  
     
     
         31 . A fibrous mat as recited by  claim 29 , said mat having a permeability of at least about 300 cfm/ft 2  measured by the Frazier test.  
     
     
         32 . A hydraulic set board, comprising: 
 a. a hydraulic set material layer having a first and a second face; and    b. first and second facers affixed to said first and second faces, at least of said first facer being a fibrous mat comprising a non-woven web bonded together with a resinous binder, and said web being composed of chopped continuous glass fibers having an average fiber diameter ranging from about 9.5 to 12.5 μm.