Fibrous mats and panels having a gypsum-based coating and methods for the manufacture thereof
AssigneeGeorgia-Pacific Gypsum LLC
InventorsYi-Hsien Harry Teng, Andrew W. Tricker
Life of this patent
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Abstract
Coated nonwoven fibrous mats, building panels, and methods for making the same are provided. A coated nonwoven fiber mat includes a nonwoven fibrous mat having a continuous barrier coating on a surface thereof. The continuous barrier coating includes a set composition of gypsum and a binder. A building panel includes a panel core associated with a coated nonwoven fiber mat. A method of making a coated nonwoven fibrous mat includes depositing a composition of water, gypsum stucco, and a binder onto a surface of a nonwoven fibrous mat and setting the composition to form a continuous barrier coating.
Claims21
A building panel, comprising:
- a panel core associated with a first nonwoven fibrous mat;
- a continuous barrier coating on a surface of the first nonwoven fibrous mat opposite the panel core, the continuous barrier coating comprising a set composition that comprises fully rehydrated gypsum hemihydrate and a binder,
- wherein the set composition comprises the rehydrated gypsum hemihydrate in an amount of from about 75 to about 97 percent, by dry weight of the composition,
- wherein the continuous barrier coating penetrates a partial portion of a thickness of the first nonwoven fibrous mat,
- wherein the panel core penetrates at least some of a remaining portion of the thickness of the first nonwoven fibrous mat.
A coated nonwoven fibrous mat, comprising:
- a nonwoven fibrous mat having a continuous barrier coating on a surface thereof,
- wherein the continuous barrier coating comprises a set composition comprising fully rehydrated gypsum hemihydrate and a binder,
- wherein the set composition comprises the rehydrated gypsum hemihydrate in an amount of from about 75 to about 97 percent, by dry weight of the composition,
- wherein the continuous barrier coating penetrates a partial portion of a thickness of the first nonwoven fibrous mat,
- wherein at least some of a remaining portion of the thickness of the first nonwoven fibrous mat is unoccupied by the continuous barrier coating.
A method of making a coated nonwoven fibrous mat, comprising:
- depositing a continuous layer of coating slurry that comprises a composition of water, gypsum hemihydrate, and a binder onto a first surface of a nonwoven fibrous mat to penetrate into a partial portion of a thickness of the nonwoven fibrous mat and to leave at least some of a remaining portion of the thickness of the nonwoven fibrous mat unoccupied by the slurry;
- and
- setting or curing the composition to fully rehydrate the gypsum hemihydrate to form a solid, continuous coating on the first surface of the nonwoven fibrous mat, wherein the solid, continuous coating comprises the fully rehydrated gypsum hemihydrate in an amount of from about 75 to about 97 percent, by dry weight of the composition.
Dependencies are inferred from the claim text.