Article of manufacture useful as wallboard and a method for the making thereof
AssigneeClemson University Research Foundation
InventorsBobby Mal Phillips, Leron Ronnie Dean
Life of this patent
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Abstract
An article of manufacture particularly suitable as wallboard, the article comprising a bonded nonwoven structure sandwiched between two layers of paper, wherein the bonded nonwoven structure comprises a binder and a load-bearing fiber wherein the load-bearing fiber has a shape factor between about 2 and 6, a short range distortion factor (SRDF) between about 5 and 70, a long range distortion factor (LRDF) between about 0.1 and 0.6, and a denier per filament (dpf) between about 3 and 200. A method of making the article is also disclosed.
Claims40
An article of manufacture comprising a bonded nonwoven structure sandwiched between two layers of paper, wherein the bonded nonwoven structure comprises a binder and a load-bearing fiber wherein the load-bearing fiber has a shape factor between about 2 and 6, a short range distortion factor (SRDF) between about 5 and 70, a long range distortion factor (LRDF) between about 0.1 and 0.6, and a denier per filament (dpf) between about 3 and 200.
A wallboard comprising a bonded nonwoven structure sandwiched between two layers of paper, wherein the bonded nonwoven structure comprises a binder and a load-bearing fiber wherein the load-bearing fiber has a shape factor between about 2 and 6, a short range distortion factor (SRDF) between about 5 and 70, a long range distortion factor (LRDF) between about 0.1 and 0.6, and a denier per filament (dpf) between about 3 and 200.
A method of making an article of manufacture, the method comprising:
- obtaining a load-bearing fiber and a binder,
- blending the load-bearing fiber and the binder to form a blended structure,
- compressing the blended structure to a desired density,
- heating the blended structure to effect bonding and to form a bonded structure,
- laminating the bonded structure between two sheets of paper, and
- securing the paper to the bonded structure.
A method of making a wallboard, the method comprising:
- obtaining a load-bearing fiber and a binder,
- blending the load-bearing fiber and the binder to form a blended structure,
- compressing the blended structure to a desired density,
- heating the blended structure to effect bonding and to form a bonded structure,
- laminating the bonded structure between two sheets of paper, and
- securing the paper to the bonded structure.
A method of making a wallboard, the method comprising:
- obtaining a load-bearing fiber and a binder,
- blending the load-bearing fiber and the binder to form a blended structure,
- laminating the blended structure between two sheets of paper,
- compressing the blended structure to a desired density,
- heating the blended structure to effect bonding and to form a bonded structure, and
- securing the paper to the bonded structure.
A method of making a wallboard, the method comprising:
- obtaining a load-bearing fiber and a binder,
- blending the load-bearing fiber and the binder to form a blended structure,
- laminating the blended structure between two sheets of paper and compressing the blended structure to a desired density,
- heating the blended structure to effect bonding and to form a bonded structure, and
- securing the paper to the bonded structure.
Dependencies are inferred from the claim text.