Membrane-ready fibrous faced gypsum panels, apparatus, and methods
AssigneesGeorgia-Pacific Gypsum LLC, Valspar Sourcing, Inc.
InventorsMichael D. Foster, Brian W. Bland, Ali Fadhel, James E. Bailey, Shaobing Wu
Life of this patent
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Abstract
Membrane-ready fibrous faced gypsum panels, methods, and apparatus are provided. The panels include a first fibrous mat having a first surface and a second surface, a second fibrous mat having a first surface and a second surface, a gypsum core in contact with the second surfaces of the first and second fibrous mats, and a material coating that covers the first surface of the first fibrous mat and forms a substantially smooth outer surface.
Claims28
A method of making an unattached, membrane-ready, exterior gypsum panel, comprising:
- depositing a gypsum slurry onto a surface of a first fibrous mat;
- depositing a second fibrous mat onto a surface of the gypsum slurry opposite the first fibrous mat, such that a surface of the second fibrous mat contacts the gypsum slurry, to form a gypsum sandwich structure;
- drying the gypsum sandwich structure;
- applying an adhesive coating composition to a surface of the first fibrous mat opposite the gypsum slurry, such that the adhesive coating covers at least a portion of the surface of the first fibrous mat;
- and
- drying the adhesive coating composition to form a material coating on the first fibrous mat and form a membrane-ready gypsum panel, wherein the material coating comprises a substantially smooth outer surface.
An apparatus for fabricating membrane-ready gypsum panels, comprising:
- a board line for transporting a first fibrous mat;
- a depositing mechanism configured to deposit a gypsum slurry onto a surface of the first fibrous mat;
- a conveyor configured to deposit a second fibrous mat onto a surface of the gypsum slurry opposite the first fibrous mat, such that a surface of the second fibrous mat contacts the gypsum slurry, to form a gypsum sandwich structure on the board line;
- a dryer for drying the gypsum sandwich structure;
- an applicator configured to apply an adhesive coating composition to a surface of the first fibrous mat opposite the gypsum slurry, such that the adhesive coating composition covers the surface of the first fibrous mat;
- and
- a dryer for drying the adhesive coating composition to provide a material coating and form a membrane-ready gypsum panel, wherein the material coating comprises a substantially smooth outer surface.
A membrane-ready gypsum panel, comprising:
- a first fibrous mat having a first surface and a second surface;
- a second fibrous mat having a first surface and a second surface;
- a gypsum core in contact with the second surfaces of the first and second fibrous mats;
- and
- a material coating that covers at least a portion of the first surface of the first fibrous mat and forms a substantially smooth outer surface thereon.
A method for coating an unattached, exterior gypsum wallboard to make the wallboard membrane-ready, comprising the steps of:
- applying an adhesive coating composition to an exposed surface of a fibrous mat of an exterior gypsum panel, wherein the adhesive coating composition comprises water and an acrylic latex;
- and
- drying the adhesive coating composition to form a material coating, wherein the coating provides a non-tacky, substantially smooth outer surface capable of adhering to an adhesive-backed membrane, and the coating composition penetrates the fibrous mat to enhance the cohesive strength thereof.
Dependencies are inferred from the claim text.