Pre-coated mat-faced gypsum board
AssigneeG-P Gypsum Corporation
InventorsBrian G. Randall, Gary A. Ricards
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Abstract
A moisture-tolerant structural panel comprising a gypsum board comprising a set gypsum core sandwiched between and faced with mats of glass fibers, wherein a free surface of one of said mats is coated with a combination of a mineral pigment, an inorganic adhesive binder and a polymer latex adhesive binder applied to said surface as an aqueous coating composition, said aqueous coating composition upon drying and setting, covering said mat to the extent that substantially none of the fibers of said mat protrude from said coating.
Claims20
A moisture-tolerant structural panel made by
- (1) contacting a gypsum slurry for forming a gypsum core with
- (2) a first surface of a coated mat comprising fibers to adhere said fibers of said first surface of said coated mat to at least one surface of said gypsum core;
- the coated mat having a coating on a second surface comprising a combination of (i) a mineral pigment, (ii) an inorganic adhesive binder and (iii) a polymer latex adhesive binder, and
- (3) allowing the gypsum slurry to harden, wherein said coated mat has a porosity which allows water to evaporate from the gypsum core during preparation of the panel.
A moisture-tolerant structural panel made by
- (1) contacting a gypsum slurry for forming a set gypsum core between two mats of glass fibers, wherein a free surface of one of said mats is coated with a combination of(i) a mineral pigment, (ii) an inorganic adhesive binder and (iii) a polymer latex adhesive binder applied to said surface as an aqueous coating composition to form a coated glass mat, said combination containing no more than about 5 wt. % polymer adhesive solids, said aqueous coating composition upon drying and setting, covering said mat to the extent that substantially none of the fibers of said mat protrude from said coating, and
- (2) allowing the gypsum slurry to harden, wherein the set gypsum core includes a water-resistant additive in an amount sufficient to improve the water-resistant properties of said core, and wherein said coated mat has a porosity which allows water to evaporate from the gypsum core during preparation of the panel.
Dependencies are inferred from the claim text.