Utility materials incorporating a microparticle matrix formed with a setting agent

Abstract

A composition, utility material, and method of making a utility material is disclosed. A composition having an improved setting time may include a plurality of microparticles mixed with a sodium silicate binder and an isocyanate setting agent, where the microparticle composition has a setting time of less than or equal to one hour. A utility material may be a wallboard that includes the composition.

What is claimed and desired to be secured by Letters Patent is: 
     
         1 . A utility material comprising:
 a wallboard having a first facing membrane and a second facing membrane; and   a core matrix disposed between the first facing membrane and the second facing membrane, wherein the core matrix includes:
 microparticles and at least one binder; 
   wherein a majority of the microparticles in the core matrix of the wallboard are structurally intact; and   wherein a water content of the wallboard is less than 5%.