# US 10,500,761 B2 · Method to improve surface finish of glass fiber mat > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,500,761 B2 - Document ID: US10500761B2 - Status: Granted - Kind: B2 - Application number: 14/467,257 - Filed: 2014-08-25 - Published: 2016-02-25 - Granted: 2019-12-10 - Earliest claimed: 2014-08-25 - Assignees: United States Gypsum Company - Applicants: United States Gypsum Company - Inventors: Alfred Li - Web page: https://patentgrep.com/patent/US10500761B2 ## CPC - B28B 19/0092: {to webs, sheets or the like, e.g. of paper, cardboard} - B29B 15/125: {by dipping} - B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)} - B32B 13/14: next to a fibrous or filamentary layer - D04H 1/4218: Glass fibres - D04H 1/60: the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently - B29K 2101/10: Thermosetting resins - B29K 2309/08: Glass - B32B 2260/021: Fibrous or filamentary layer - B32B 2260/046: Synthetic resin - B32B 2262/101: Glass fibres - B32B 2607/00: Walls, panels - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) - B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS ## Abstract A durable, moisture-resistant gypsum product is provided with smooth furnish which comprises a laminated glass fiber mat in which glass fibers are compressed and cross-linked with a thermosetting polymeric resin. Methods for making these gypsum products and glass fiber mats are provided as well. ## Claims ### Claim 1 A method for making a gypsum product, the method comprising: obtaining a glass fiber mat; laminating the glass fiber mat with a thermosetting polymeric resin by soaking the glass fiber mat in the thermosetting polymeric resin; partially curing the thermosetting polymeric resin; after the thermosetting polymeric resin is partially cured, but before the thermosetting polymeric resin is fully cured, compressing glass fibers in the glass fiber mat by at least one of the following means: in a wet press under a pressure in the range from 5 psi to 100 psi, and/or by a calendar; curing the thermosetting polymeric resin by exposing it to heat; preparing a gypsum slurry; depositing the gypsum slurry onto the cured laminated glass fiber mat; and letting the gypsum product set. ### Claim 2 (depends on 1) The method of claim 1, where the cured laminated glass fiber mat has a face side and a back side, and the back side is in contact with the gypsum slurry. ### Claim 3 (depends on 1) The method of claim 1, wherein glass fibers in the glass fiber mat are compressed to produce a level 5 finish for the gypsum product. ### Claim 4 (depends on 2) The method claim 2, wherein the fibers on the face side are compressed. ### Claim 5 (depends on 1) The method of claim 1, wherein the thermosetting polymeric resin is an acrylic binder. ### Claim 6 (depends on 1) The method of claim 1, wherein the gypsum slurry further comprises at least one of the following: foam, natural fibers, synthetic fibers, a defoamer, a plastisizer, a filler and a binder. ### Claim 7 A method for making a laminated glass fiber mat, the method comprising: obtaining a glass fiber mat; soaking it in a thermosetting polymeric resin; partially curing the thermosetting polymeric resin; after the thermosetting polymeric resin is partially cured, but before the thermosetting polymeric resin is fully cured, compressing the fibers in the glass fiber mat with a wet press under the pressure in the range from 5 psi to 100 psi and/or by a calendar; and curing the laminated glass fiber mat in a dryer. ### Claim 8 (depends on 7) The method of claim 7, wherein the glass fiber mat is further pressed with a dry press before it is soaked. ### Claim 9 (depends on 7) The method of claim 7, wherein the glass fiber mat is further calendared after the resin is cured. ### Claim 10 (depends on 7) The method of claim 7, wherein the glass fiber mat is further calendared before the resin is fully cured. ### Claim 11 (depends on 7) The method of claim 7, wherein a calendar is used in place of a wet press and the resin is only partially cured with a first dryer before the calendaring step. ### Claim 12 (depends on 11) The method of claim 11, wherein the resin is cured to completion with a second dryer after the calendaring step. ### Claim 13 (depends on 1) The method of claim 1, wherein the thermosetting polymeric resin is selected from a polyacrylate, polystyrene, polyester, polyethylene, polypropylene, polybutylene and mixtures thereof. ### Claim 14 (depends on 1) The method of claim 1, wherein the step of compressing comprises applying a pressure of up to 60 psi.