New gypsum board and systems comprising it

A gypsum board comprising at least one mat-facer, wherein said at least one mat-facer comprises at least two plies, an inner ply and an outer ply, where the inner ply is in contact with the core of said gypsum board and comprises a mixture of cellulose fibers, inorganic or mineral fibers and organic fibers, and said outer ply comprises essentially cellulose fibers, wherein said mat-facer further comprises at least a binder and at least mineral filler particles, said particles are distributed substantially fully into both said inner and said outer ply, and wherein the inner ply comprises, by weight based on the total weight of the fibers, from 30 to 50 wt % of cellulose fibers, from 30 to 50 wt % of glass fibers, and from 10 to 20 wt % of organic fibers.

A gypsum board comprising at least one mat-facer, wherein said at least one mat-facer comprises at least two plies, an inner ply and an outer ply, and wherein the core comprises water-resistant additive in an amount sufficient such that the core absorbs less than about 10% water when tested in accordance with ASTM method C-473 and wherein the core comprises fire-resistant additive in an amount sufficient such that the board achieves an ASTM E-119 fire rating of at least about one hour.

An exterior insulation system for a building comprising a mat-facer gypsum board, insulating material having an inner surface and an outer surface, the inner surface of which is adhered to the surface of the mat-facer of said gypsum board by an adhesive material, and an exterior finishing material overlying the outer surface of said insulating material, wherein said mat-facer of the gypsum board comprises at least two plies, an inner ply and an outer ply, where the inner ply is in contact with the core of said gypsum board and comprises a mixture of cellulose fibers, inorganic or mineral fibers and optionally organic fibers, and said outer ply comprises essentially cellulose fibers.

An exterior insulation system for a building comprising a mat-facer gypsum board, insulating material having an inner surface and an outer surface, the inner surface of which is adhered to the surface of the mat-facer of said gypsum board by an adhesive material, and an exterior finishing material overlying the outer surface of said insulating material, wherein said mat-facer of the gypsum board comprises at least two plies, an inner ply and an outer ply, where the inner ply is in contact with the core of said gypsum board and where said mat-facer comprises a fibrous nonwoven inner ply and an outer ply, said inner ply and said outer ply comprising fibers or particles or both, the fibers in the inner ply and the fibers or particles or both in the outer ply being bonded together with a same resinous binder.

An exterior finishing system for a building comprising an underlying structural support element which is covered with an overlying finishing material, said support element including mat-facer gypsum board comprising a set gypsum core sandwiched between two sheets of facers, the gypsum core including water-resistant additives in an amount at least sufficient to impart to the core improved water-resistant properties, wherein said mat-facer of the gypsum board comprises at least two plies, an inner ply and an outer ply, where the inner ply is in contact with the core of said gypsum board and comprises a mixture of cellulose fibers, glass fibers and optionally organic fibers, and said outer ply comprises essentially cellulose fibers.

An exterior finishing system for a building comprising an underlying structural support element which is covered with an overlying finishing material, said support element including mat-facer gypsum board comprising a set gypsum core sandwiched between two sheets of facers, the gypsum core including water-resistant additives in an amount at least sufficient to impart to the core improved water-resistant properties, wherein said mat-facer of the gypsum board comprises at least two plies, an inner ply and an outer ply, where the inner ply is in contact with the core of said gypsum board and where said mat-facer comprises a fibrous nonwoven inner ply and an outer ply, said inner ply and said outer ply comprising fibers or particles or both, the fibers in the inner ply and the fibers or particles or both in the outer ply being bonded together with a same resinous binder.

An internal wet or humid area partition assembly system comprising metal or wood framework or studs for support of a board, said board including a mat-facer gypsum board comprising a set gypsum core sandwiched between two sheets of facers, the gypsum core including water-resistant additives in an amount at least sufficient to impart to the core improved water-resistant properties, wherein said mat-facer of the gypsum board comprises at least two plies, an inner ply and an outer ply, where the inner ply is in contact with the core of said gypsum board and comprises a mixture of cellulose fibers, inorganic or mineral fibers and optionally organic fibers, and said outer ply comprises essentially cellulose fibers.

An internal wet or humid area partition assembly system comprising metal or wood framework or studs for support of a board, said board including a mat-facer gypsum board comprising a set gypsum core sandwiched between two sheets of facers, the gypsum core including water-resistant additives in an amount at least sufficient to impart to the core improved water-resistant properties, wherein said mat-facer of the gypsum board comprises at least two plies, an inner ply and an outer ply, where the inner ply is in contact with the core of said gypsum board and where said mat-facer comprises a fibrous nonwoven inner ply and an outer ply, said inner ply and said outer ply comprising fibers or particles or both, the fibers in the inner ply and the fibers or particles or both in the outer ply being bonded together with a same resinous binder.