US4810569A — Fibrous mat-faced gypsum board

Claim 1

Independent Claim 99 words

Gypsum board comprising a set gypsum core sandwiched between two sheets of porous glass mat, each of which has an inner and outer surface, said mat comprising randomly distributed glass fibers bonded by an adhesive material, the inner surface of each of said mats adhered to said gypsum core by a portion of the set gypsum comprising said core, the outer surface of one of said mats having portions thereof coated with set gypsum comprising portions of the set gypsum of said core, and the outer surface of the other of said mats being substantially free of set gypsum.

Claim 2

Dependent Claim 99 words

Gypsum board comprising a set gypsum core sandwiched between two sheets of porous glass mat, each of which has an inner and outer surface, said mat comprising randomly distributed glass fibers bonded by an adhesive material, the inner surface of each of said mats adhered to said gypsum core by a portion of the set gypsum comprising said core, the outer surface of one of said mats having portions thereof coated with set gypsum comprising portions of the set gypsum of said core, and the outer surface of the other of said mats being substantially free of set gypsum.

Claim 3

Dependent Claim 24 words

Gypsum board according to claim 1 wherein said mat is a glass fiber mat comprising randomly distributed glass filaments bonded by an adhesive material.

Claim 4

Dependent Claim 61 words

Gypsum board in accordance with claim 1 wherein each of said mats comprises randomly distributed glass filaments bonded by an adhesive material, wherein said gypsum-coated mat is substantially penetrated by set gypsum over substantial area portions of the outer surface thereof, and wherein the set gypsum of the core penetrates but part-way into the thickness of the other of said mats.

Claim 5

Dependent Claim 28 words

Gypsum board in accordance with claim 3 wherein about 45 to about 55% of the outer surface of said gypsum-coated mat is substantially penetrated by the set gypsum.

Claim 6

Dependent Claim 47 words

Gypsum board in accordance with claim 1 or 3 in the form of a package in which two of said boards are packaged with said gypsum-free outer surfaces in face to face relationship and in which said gypsum-coated outer surfaces form the outer surfaces of said package.

Claim 7

Dependent Claim 86 words

Gypsum board comprising a set gysum core sandwiched between two sheets of porous glass mat, each of which has an inner and outer surface and a predetermined thickness, said mat comprising randomly distributed glass fibers bonded by an adhesive material, the inner surface of each of said mats adhered to said gypsum core by set gypsum of said core penetrating but part-way into the thickness of each of said mats, and wherein the outer surface of each of said mats is substantially free of set gypsum.

Claim 8

Dependent Claim 86 words

Gypsum board comprising a set gysum core sandwiched between two sheets of porous glass mat, each of which has an inner and outer surface and a predetermined thickness, said mat comprising randomly distributed glass fibers bonded by an adhesive material, the inner surface of each of said mats adhered to said gypsum core by set gypsum of said core penetrating but part-way into the thickness of each of said mats, and wherein the outer surface of each of said mats is substantially free of set gypsum.

Claim 9

Dependent Claim 103 words

Gypsum board comprising a set gypsum core sandwiched between two sheets of porous glass mat, each of which has an inner and outer surface, said mat oomprising randomly distributed glass fibers bonded by an adhesive material, the inner surface of each of said mats adhered to said gypsum core by set gypsum of said core penetrating but part-way into the thickness of each of said mats, with the interstices between the fibers at the inner surface of each of said mats being substantially filled with set gypsum, and wherein the outer surface of each of said mats is substantially free of set gypsum.

Claim 10

Dependent Claim 103 words

Gypsum board comprising a set gypsum core sandwiched between two sheets of porous glass mat, each of which has an inner and outer surface, said mat oomprising randomly distributed glass fibers bonded by an adhesive material, the inner surface of each of said mats adhered to said gypsum core by set gypsum of said core penetrating but part-way into the thickness of each of said mats, with the interstices between the fibers at the inner surface of each of said mats being substantially filled with set gypsum, and wherein the outer surface of each of said mats is substantially free of set gypsum.

Claim 11

Dependent Claim 112 words

Gypsum board comprising the set product of an aqueous slurry of calcined gypsum of predetermined viscosity sandwiched between underlying and overlying sheets of porous glass mat, each of which has an inner and outer surface and a predetermined thickness, said mat comprising randomly distributed glass fibers bonded by an adhesive material, wherein the relationship of the viscosity of said slurry to the porosity and thickness of each of said mats is such that said slurry penetrates but part-way into the thickness of each of said mats as said slurry sets to form a set gypsum core having adhered thereto said mats, the outer surfaces of which are substantially free of set gypsum.

Claim 12

Dependent Claim 112 words

Gypsum board comprising the set product of an aqueous slurry of calcined gypsum of predetermined viscosity sandwiched between underlying and overlying sheets of porous glass mat, each of which has an inner and outer surface and a predetermined thickness, said mat comprising randomly distributed glass fibers bonded by an adhesive material, wherein the relationship of the viscosity of said slurry to the porosity and thickness of each of said mats is such that said slurry penetrates but part-way into the thickness of each of said mats as said slurry sets to form a set gypsum core having adhered thereto said mats, the outer surfaces of which are substantially free of set gypsum.

Claim 13

Dependent Claim 38 words

Gypsum board according to claim 8 wherein the thickness of each of said mats is about 15 to about 40 mils and wherein the viscosity of said slurry is about 5000 to about 7000 cp at 70° F.

Claim 14

Dependent Claim 21 words

Gypsum board according to claim 9 wherein said slurry penetrates about 10 to 50% of the thickness of the overlying mat.

Claim 15

Dependent Claim 21 words

Gypsum board according to claim 9 wherein said slurry penetrates up to about 50% of the thickness of said underlying mat.

Claim 16

Dependent Claim 17 words

Gypsum board according to claim 8, 9, 10, or 11 wherein said set product includes paper fiber.

Claim 17

Dependent Claim 20 words

Gypsum board according to claim 12 wherein the air permeability of each of said mats is about 700 CFM/sq. ft.

Claim 18

Dependent Claim 21 words

Gypsum board according to claim 12 wherein the thickness of each of said mats is about 25 to about 35 mils.

Claim 19

Dependent Claim 105 words

Gypsum board comprising a set gypsum core sandwiched between two sheets of porous glass fiber mat, each of the mats having an inner and outer surface, the inner surface of each of said mats adhered to said gypsum core by set gypsum of said core penetrating but part-way into the thickness of each of said mats, with the interstices between the fibers at the inner surface of each of said mat being substantially filled with set gypsum, and the outer surface of each of said mats being substantially free of set gypsum and comprising many interstices into which an adhesive composition can flow and bond.

Claim 20

Dependent Claim 105 words

Gypsum board comprising a set gypsum core sandwiched between two sheets of porous glass fiber mat, each of the mats having an inner and outer surface, the inner surface of each of said mats adhered to said gypsum core by set gypsum of said core penetrating but part-way into the thickness of each of said mats, with the interstices between the fibers at the inner surface of each of said mat being substantially filled with set gypsum, and the outer surface of each of said mats being substantially free of set gypsum and comprising many interstices into which an adhesive composition can flow and bond.

Claim 21

Dependent Claim 21 words

Gypsum board according to claim 15 wherein each of said mats comprises randomly distributed glass fibers bonded by an adhesive material.

Claim 22

Dependent Claim 202 words

A process for manufacturing in continuous fashion a glass fiber mat-faced gypsum board of indefinite length comprising: (A) forming an aqueous slurry of calcined gypsum; (B) continuously feeding said aqueous slurry onto an underlying, moving and supported porous glass fiber mat having an outer surface; (C) forming said deposited slurry as it is carried on said moving mat into a panel-like shape; (D) applying to the top surface of said panel-like shape of slurry an overlying porous glass fiber mat of predetermined thickness; (E) maintaining the viscosity of said slurry at a value such that said underlying mat is substantially penetrated by said slurry over substantial area portions of the outer surface thereof, and at a value such that portions of said slurry penetrate but part-way into the thickness of said overlying mat; and (F) maintaining said panel-like shape as said calcined gypsum sets to form a set gypsum core having adhered to one surface thereof said underlying glass fiber mat which is substantially penetrated by set gypsum over substantial area portions of the outer surface thereof, and the core having adhered to its other surface said overlying glass fiber mat, the outer surface of which is substantially free of set gypsum.

Claim 23

Dependent Claim 202 words

A process for manufacturing in continuous fashion a glass fiber mat-faced gypsum board of indefinite length comprising: (A) forming an aqueous slurry of calcined gypsum; (B) continuously feeding said aqueous slurry onto an underlying, moving and supported porous glass fiber mat having an outer surface; (C) forming said deposited slurry as it is carried on said moving mat into a panel-like shape; (D) applying to the top surface of said panel-like shape of slurry an overlying porous glass fiber mat of predetermined thickness; (E) maintaining the viscosity of said slurry at a value such that said underlying mat is substantially penetrated by said slurry over substantial area portions of the outer surface thereof, and at a value such that portions of said slurry penetrate but part-way into the thickness of said overlying mat; and (F) maintaining said panel-like shape as said calcined gypsum sets to form a set gypsum core having adhered to one surface thereof said underlying glass fiber mat which is substantially penetrated by set gypsum over substantial area portions of the outer surface thereof, and the core having adhered to its other surface said overlying glass fiber mat, the outer surface of which is substantially free of set gypsum.

Claim 24

Dependent Claim 36 words

A process according to claim 17 wherein said mat comprises randomly distributed glass filaments bonded by an adhesive material and wherein the viscosity of said slurry is about 5000 to about 7000 cp at 70° F.

Claim 25

Dependent Claim 155 words

A process for manufacturing in continuous fashion a glass fiber mat-faced gypsum board of indefinite length comprising: (A) forming an aqueous slurry of calcined gypsum; (B) continuously feeding said aqueous slurry onto an underlying, moving and supported porous glass fiber mat having an outer surface and a predetermined thickness; (C) forming said deposited slurry as it is carried on said moving mat into a panel-like shape; (D) applying to the top surface of said panel-like shape of slurry an overlying porous glass fiber mat having an outer surface and a predetermined thickness; (E) maintaining the viscosity of said slurry at a value such that portions of said slurry penetrate but part-way into the thickness of each of said underlying and overlying mats; and (F) maintaining said panel-like shape as said calcined gypsum sets to form a set gypsum core having adhered thereto said mats, the outer surfaces of which are substantially free of set gypsum.

Claim 26

Dependent Claim 155 words

A process for manufacturing in continuous fashion a glass fiber mat-faced gypsum board of indefinite length comprising: (A) forming an aqueous slurry of calcined gypsum; (B) continuously feeding said aqueous slurry onto an underlying, moving and supported porous glass fiber mat having an outer surface and a predetermined thickness; (C) forming said deposited slurry as it is carried on said moving mat into a panel-like shape; (D) applying to the top surface of said panel-like shape of slurry an overlying porous glass fiber mat having an outer surface and a predetermined thickness; (E) maintaining the viscosity of said slurry at a value such that portions of said slurry penetrate but part-way into the thickness of each of said underlying and overlying mats; and (F) maintaining said panel-like shape as said calcined gypsum sets to form a set gypsum core having adhered thereto said mats, the outer surfaces of which are substantially free of set gypsum.

Claim 27

Dependent Claim 211 words

A process for manufacturing in continuous fashion a glass fiber mat-faced board of indefinite length comprising: (A) forming an aqueous slurry of calcined gypsum; (B) continuously feeding said aqueous slurry onto an underlying, moving and supported porous glass fiber mat having an inner and outer surface and a predetermined thickness; (C) forming said deposited slurry as it is carried on said moving mat into a panel-like shape; (D) applying to the top surface of said panel-like shape of slurry an overlying porous glass fiber mat having an inner and outer surface and a predetermined thickness; (E) maintaining the viscosity of said slurry at a value such that the relationship between the viscosity of said slurry to the porosity and thickness of each of said underlying and overlying mats is such that said slurry penetrates but part-way into the thickness of each of said mats; and (F) maintaining said panel-like shape as said calcined gypsum sets to form a set gypsum core to which said underlying and overlying mats are adhered by said set gypsum which substantially fills the interstices between the individual glass fibers at the inner surfaces of said mats, with the interstices between the individual fibers at the outer surfaces of said mats being substantially free of set gypsum.

Claim 28

Dependent Claim 211 words

A process for manufacturing in continuous fashion a glass fiber mat-faced board of indefinite length comprising: (A) forming an aqueous slurry of calcined gypsum; (B) continuously feeding said aqueous slurry onto an underlying, moving and supported porous glass fiber mat having an inner and outer surface and a predetermined thickness; (C) forming said deposited slurry as it is carried on said moving mat into a panel-like shape; (D) applying to the top surface of said panel-like shape of slurry an overlying porous glass fiber mat having an inner and outer surface and a predetermined thickness; (E) maintaining the viscosity of said slurry at a value such that the relationship between the viscosity of said slurry to the porosity and thickness of each of said underlying and overlying mats is such that said slurry penetrates but part-way into the thickness of each of said mats; and (F) maintaining said panel-like shape as said calcined gypsum sets to form a set gypsum core to which said underlying and overlying mats are adhered by said set gypsum which substantially fills the interstices between the individual glass fibers at the inner surfaces of said mats, with the interstices between the individual fibers at the outer surfaces of said mats being substantially free of set gypsum.

Claim 29

Dependent Claim 152 words

A process for manufacturing in continuous fashion a glass mat-faced gypsum board of indefinite length comprising: (A) forming an aqueous slurry of calcined gypsum; (B) continuously feeding said aqueous slurry onto an underlying, moving and supported porous glass mat having an outer surface and a predetermined thickness; (C) forming said deposited slurry as it is carried on said moving mat into a panel-like shape; (D) applying to the top surface of said panel-like shape of slurry on overlying porous glass mat having an outer surface and a predetermined thickness; (E) including in said slurry paper fibers in an amount such that portions of said slurry penetrate but part-way into the thickness of each of said underlying and overlying mats; and (F) maintaining said panel-like shape as said calcined gypsum sets to form a set gypsum core having adhered thereto said mats, the outer surfaces of which are substantially free of set gypsum.

Claim 30

Dependent Claim 152 words

A process for manufacturing in continuous fashion a glass mat-faced gypsum board of indefinite length comprising: (A) forming an aqueous slurry of calcined gypsum; (B) continuously feeding said aqueous slurry onto an underlying, moving and supported porous glass mat having an outer surface and a predetermined thickness; (C) forming said deposited slurry as it is carried on said moving mat into a panel-like shape; (D) applying to the top surface of said panel-like shape of slurry on overlying porous glass mat having an outer surface and a predetermined thickness; (E) including in said slurry paper fibers in an amount such that portions of said slurry penetrate but part-way into the thickness of each of said underlying and overlying mats; and (F) maintaining said panel-like shape as said calcined gypsum sets to form a set gypsum core having adhered thereto said mats, the outer surfaces of which are substantially free of set gypsum.

Claim 31

Dependent Claim 15 words

A process according to claim 19 or 20, including adding to said slurry paper fibers.

Claim 32

Dependent Claim 26 words

A process according to claim 19, 20 or 21 wherein said mats are glass fiber mats comprising randomly distributed glass filaments bonded by an adhesive material.

Claim 33

Dependent Claim 21 words

A process according to claim 23 wherein the thickness of each of said mats is about 15 to about 40 mils.

Claim 34

Dependent Claim 21 words

A process according to claim 24, wherein the thickness of each of said mats is about 25 to about 35 mils.

Claim 35

Dependent Claim 22 words

A process according to claim 24, wherein the viscosity of said slurry is about 5000 to about 7000 cp at 70° F.

Claim 36

Dependent Claim 20 words

A process according to claim 26, wherein the air permeability of each of said mats is about 700 CFM/sq. ft.

Claim 37

Dependent Claim 24 words

A process according to claim 19, 20 or 21 wherein said slurry penetrates up to about 50% of the thickness of said underlying mat.

Claim 38

Dependent Claim 23 words

A process according to claim 28 wherein said mats are glass fiber mats comprising randomly distributed glass filaments bonded by an adhesive material.

Claim 39

Dependent Claim 24 words

A process according to claim 19, 20 or 21 wherein said slurry penetrates about 10 to 50% of the thickness of the overlying mat.

Claim 40

Dependent Claim 23 words

A process according to claim 30 wherein said mats are glass fiber mats comprising randomly distributed glass filaments bonded by an adhesive material.

Claim 41

Dependent Claim 21 words

A process according to claim 31 wherein said slurry penetrates up to about 50% of the thickness of said underlying mat.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1992-03-06	1992-09-05	1993-03-07	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1996-03-06	1996-09-05	1997-03-07	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2000-03-06	2000-09-05	2001-03-07	$7700.00	Window Closed / Lapsed

Fibrous mat-faced gypsum board

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