Gypsum board having improved flexibility, toughness, abuse resistance, water resistance and fire resistance
AssigneeE. I. Du Pont de Nemours and Company
InventorsRobert B. Bruce, Ashok Harakhlal Shah
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Abstract
The present invention relates to a gypsum board having a nonwoven liner and a gypsum core. The gypsum board of the present invention has a high work to break, resulting in a gypsum board product that has a high resistance to abuse in use. The gypsum board of the invention is also more flexible and more resistant to water and fire than paper-lined gypsum board, and does not contain nutrients that support mold growth.
Claims48
A gypsum board comprising a gypsum core held between two sheets of porous, fibrous polymeric nonwoven liner, wherein the work-to-break of the gypsum board in the MD of the nonwoven liner at a strain of 0.75 inch is greater than 30 lb-in.
An improved gypsum board comprising a gypsum core held between two sheets of porous, fibrous polymeric nonwoven liner, wherein the work-to-break of the board in the MD at a strain of 0.75 inch is greater than 60*X lb.-in. where X is the thickness of the board in inches.
A gypsum board comprising a gypsum core held between two sheets of porous, fibrous polymeric nonwoven liner, wherein the nonwoven liner has strip tensile in the MD of at least 35 lb./in., percent elongation at 1 lb. in the MD of less than 0.7%, percent elongation at 3 lb. in the MD of less than 1.5% and percent elongation-at-break in the MD of less than 100%, strip tensile in the CD of at least 12 lb./in., percent elongation at 1 lb. in the CD of less than 3.0%, percent elongation at 3 lb. in the CD of less than 7.0% and percent elongation-at-break in the CD of less than 300%.
A gypsum board comprising a gypsum core held between two sheets of porous, fibrous polymeric nonwoven liner, wherein the nonwoven liner has strip tensile in the MD of at least 65 lb./in., percent elongation at 1 lb. in the MD of less than 0.5%, percent elongation at 3 lb. in the MD of less than 0.7% and percent elongation-at-break in the MD of less than 50%, strip tensile in the CD of at least 22 lb./in., percent elongation at 1 lb. in the CD of less than 1.5%, percent elongation at 3 lb. in the CD of less than 3.0% and percent elongation-at-break in the CD of less than 100%.
Dependencies are inferred from the claim text.