US20170326840A1 - Method for preparing mat-faced board - Google Patents
Method for preparing mat-faced board Download PDFInfo
- Publication number
- US20170326840A1 US20170326840A1 US15/484,873 US201715484873A US2017326840A1 US 20170326840 A1 US20170326840 A1 US 20170326840A1 US 201715484873 A US201715484873 A US 201715484873A US 2017326840 A1 US2017326840 A1 US 2017326840A1
- Authority
- US
- United States
- Prior art keywords
- mat
- region
- board
- core
- face
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/724—Permeability to gases, adsorption
- B32B2307/7242—Non-permeable
- B32B2307/7246—Water vapor barrier
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2307/00—Properties of the layers or laminate
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- B32B2307/726—Permeability to liquids, absorption
- B32B2307/7265—Non-permeable
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/728—Hydrophilic
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/73—Hydrophobic
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2419/00—Buildings or parts thereof
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2607/00—Walls, panels
Definitions
- Gypsum wallboard having a gypsum-based core reinforced on the outer major surfaces with a facing material or scrim is well-known in the art.
- the facing material is often paper for typically dry environments, e.g., for indoor drywall products.
- a glass or polymer-based mat is used in products that may be exposed to high moisture conditions.
- such board is useful in exterior sheathing products.
- the glass-mat gypsum board sheathing can be applied to outer studs, joists, or rafters of a home or commercial building to strengthen the structure and provide fire resistance and a degree of water resistance.
- the sheathing provides a base for exterior cladding (e.g., bricks, siding, stone, etc.) to be applied, with an additional moisture and vapor barrier substrate optionally applied there between.
- Glass-mat gypsum board can also be utilized in indoor applications where the board may be exposed to significant moisture.
- glass-mat faced board can be used in a variety of indoor locations, such as in sink or tub enclosures, backsplashes, etc.
- the glass-mat faced board provides a base for ceramic tile or the like to be applied, e.g., using mortar or mastic to secure the tile to the base.
- the glass mat provides a degree of water resistance and mold resistance over time in case water penetrates through the set mortar or mastic, e.g. through cracks in the tile or grout.
- mat-faced gypsum board typically involves depositing cementitious slurry (e.g., a mixture containing stucco and water, where stucco refers to calcined gypsum, typically comprised primarily of calcium sulfate hemihydrate and/or calcium sulfate anhydrite) over a first mat facing material and covering the wet slurry with a second mat facing material, usually of the same type, such that the cementitious slurry is sandwiched between the two mat facing materials.
- cementitious slurry e.g., a mixture containing stucco and water, where stucco refers to calcined gypsum, typically comprised primarily of calcium sulfate hemihydrate and/or calcium sulfate anhydrite
- the cementitious slurry is allowed to harden (e.g., forming an interlocking matrix of calcium sulfate dihydrate, referred to as set gypsum) to produce a solid article prior to final drying in a kiln.
- set gypsum an interlocking matrix of calcium sulfate dihydrate
- mat-faced gypsum board thus, often requires the facing material to be sufficiently permeable that excess water can be removed from the cementitious slurry in the drying process.
- non-woven fiberglass mat is often used as the facing material, in which the space between the fibers provides permeability.
- the permeability of the fibrous mat facing material if not treated, could reduce the water-resistance of the cementitious article because it allows water to penetrate the mat and contact the cementitious core during use.
- exterior coatings of water resistant material are sometimes applied.
- the disclosure provides a facer mat for use as a cover sheet with board products (e.g., gypsum or cement board).
- the mat comprises an outer surface and an inner surface.
- the mat also includes a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first substantial thickness.
- the mat also includes a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second substantial thickness.
- the first region is more hydrophilic than the second region.
- the disclosure provides another mat for use as a cover sheet with gypsum board, the mat comprising an outer surface and an inner surface.
- the mat also includes a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first substantial thickness.
- the mat also includes a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second substantial thickness. The first region is more wettable than the second region.
- the disclosure provides another mat for use as a cover sheet for gypsum board.
- the mat comprises an outer surface and an inner surface.
- the mat also includes a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first substantial thickness.
- the mat also includes a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second substantial thickness. The first region is less dense than the second region.
- the disclosure provides gypsum board comprising a gypsum core disposed between two cover sheets.
- the core has a face surface and a back surface.
- At least one cover sheet is a mat (e.g., containing glass fiber).
- a face mat faces a face surface of the core, and a back mat faces a back surface of the core.
- the gypsum core comprises set gypsum, e.g., a crystalline matrix of set gypsum.
- the face mat, and optionally the back mat has an outer surface and an inner surface.
- the face mat, and optionally the back mat comprises a first region adjacent to the outer surface of the mat defined along a horizontal plane of the mat, the first region having a first substantial thickness.
- the face mat, and optionally the back mat also comprises a second region adjacent to the inner surface of the mat defined along a horizontal plane of the mat, the second region having a second substantial thickness.
- the first region is more hydrophilic than the second region.
- the disclosure provides another gypsum board comprising a gypsum core disposed between two cover sheets.
- the gypsum core generally comprises set gypsum, e.g., a crystalline matrix of set gypsum in preferred embodiments.
- the core has a face surface and a back surface.
- One or both of the cover sheets is in the form of a mat (e.g., containing glass fiber).
- a face mat faces a face surface of the core, and, optionally, a back mat faces a back surface of the core.
- the face mat, and optionally the back mat has an outer surface and an inner surface.
- the face mat, and optionally the back mat comprises a first region adjacent to the outer surface of the mat defined along a horizontal plane of the mat, the first region having a first substantial thickness (relative to the entire thickness of the mat).
- the face mat, and optionally the back mat also comprises a second region adjacent to the inner surface of the mat defined along a horizontal plane of the mat, the second region having a second substantial thickness.
- the first region is more wettable than the second region.
- the disclosure provides another gypsum board comprising a gypsum core disposed between two cover sheets.
- the gypsum core generally comprises set gypsum, e.g., a crystalline matrix of set gypsum in preferred embodiments.
- the core has a face surface and a back surface.
- One or both of the cover sheets is in the form of a mat (e.g., containing glass fiber).
- a face mat faces a face surface of the core, and, optionally, a back mat faces a back surface of the core.
- the face mat, and optionally the back mat has an outer surface and an inner surface.
- the face mat, and optionally the back mat comprises a first region adjacent to the outer surface of the mat defined along a horizontal plane of the mat, the first region having a first substantial thickness (relative to the entire thickness of the mat).
- the face mat, and optionally the back mat also comprises a second region adjacent to the inner surface of the mat defined along a horizontal plane of the mat, the second region having a second substantial thickness.
- the first region is less dense than the second region.
- the disclosure provides a method of manufacturing gypsum board.
- the method can be in the form of making composite gypsum board (i.e., gypsum core with a face mat adjacent to a face surface of the core, and optionally a cover sheet adjacent to a back surface of the core).
- the method generally comprises mixing at least water, stucco, and optionally one or more additives to form a slurry (e.g., in a pin or pin-less mixer).
- the slurry is applied to form a board core in a direct or indirect bonding relation to a face mat.
- the board core has a face surface and a back surface, wherein the face surface faces the face mat.
- a back mat is applied to the core slurry to form a board precursor.
- At least one mat comprises a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first substantial thickness, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second substantial thickness.
- the first region is more hydrophilic than the second region.
- another method of making composite gypsum board comprises mixing at least water, stucco, and optionally one or more additives to form slurry.
- the slurry is applied to form a board core in a direct or indirect bonding relation to a face mat.
- the board core has a face surface and a back surface, wherein the face surface faces the face mat.
- a back mat is applied to the core slurry to form a board precursor.
- the board precursor is dried to form the board.
- At least one mat comprises a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first substantial thickness, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second substantial thickness. The first region is less dense than the second region.
- the disclosure provides another method of making composite gypsum board.
- the method comprises mixing at least water, stucco, and optionally one or more additives to form slurry.
- the slurry is applied to form a board core in a direct or indirect bonding relation to a face mat.
- the board core has a face surface and a back surface, wherein the face surface faces the face mat.
- a back mat is applied to the core slurry to form a board precursor.
- the board precursor is dried to form the board.
- At least one mat comprises a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first substantial thickness, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second substantial thickness.
- the first region is more hydrophilic than the second region.
- the disclosure provides a method of making a mat for use as a cover sheet in board products.
- the method comprises introducing fibers to wet felting processing or the like to form a mat having an outer surface and an inner surface.
- the fibers can be in the form of, for example, glass, thermoplastic, or thermoset fiber.
- the mat is prepared to have a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first thickness.
- the mat is prepared to have a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second thickness.
- the mat is prepared such that the first region is more hydrophilic than the second region.
- another method of preparing a mat for use as a cover sheet with board comprises introducing fibers to wet felting processing or the like to form a mat having an outer surface and an inner surface.
- the fibers can be in the form of, for example, glass, thermoplastic, or thermoset fiber.
- the mat is prepared to have a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first thickness.
- the mat is also prepared to also include a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second thickness.
- the first region is prepared to be more wettable than the second region.
- the disclosure provides another method of preparing a mat for use as a cover sheet with board.
- the method comprises introducing fibers to wet felting processing or the like to form a mat having outer and inner surfaces.
- the fibers can be in the form of, for example, glass, thermoplastic, or thermoset fiber.
- the mat is prepared to have a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first thickness.
- the mat is also prepared to have a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second thickness.
- the first region is prepared to be less dense than the second region.
- FIG. 1 schematically illustrates a cross-sectional view of an embodiment of a cementitious board with a core sandwiched between two mats (not to scale).
- Embodiments of the disclosure provide an improved facer mat, as well as gypsum board containing such mat facers on one or both major surfaces of the board (face and back sides when installed), a method of manufacturing such board, and a method of making the mat.
- the facer according to embodiments of the disclosure more preferentially receives coatings, e.g., in a continuous manufacturing method.
- the improved glass mat of the disclosure accepts coatings readily and results in a more robust and efficient manufacturing process. Coatings can be applied with good flow and coverage on the mat, with good uniformity and less coating defects. During production, less board is required to be culled, such that board production yields can improve.
- the mat facer of the disclosure allows for less loss of coating material by seepage into and/or through the mat.
- use of the facer mat in accordance with preferred embodiments results in a more efficient manufacturing process.
- the disclosure reduces or avoids the need for any wetting aids in the coating that is applied.
- the mat in accordance with embodiments of the disclosure, includes an outer surface and an inner surface.
- a gypsum core is sandwiched between two mat facers.
- One mat facer is referred to herein as the face mat, and the other facer is referred to as the back mat.
- a board 10 includes a face mat 12 having an outer surface 14 which is generally facing exterior cladding of a building structure (with an optional moisture and/or vapor barrier substrate disposed there between), while an inner surface 16 of the mat 12 faces, and optionally directly or indirectly affixes to, to a face surface 18 of a gypsum core 20 .
- a back mat 22 On the back side of the board 10 , a back mat 22 has an outer surface 24 generally facing the studs, rafters, or joists of a structure.
- the studs, rafters, or joists can be made of any suitable material, including a wood material or metal (e.g., steel).
- An inner surface 26 of the back mat 22 faces, and optionally directly or indirectly affixes to, a back surface 28 of the gypsum core 20 .
- FIG. 1 shows mats 12 and 22 having different regions exhibiting different properties or densities. It will be understood that only one of the mats can have the regions if desired.
- the face mat 12 includes a first region 30 , which is adjacent to the outer surface 14 of the mat 12 , and a second region 32 , which is adjacent to the inner surface 16 of the mat 12 .
- the back mat 22 includes a third region 34 , which is adjacent to the outer surface of the mat 24 , and a fourth region, 36 which is adjacent to the inner surface of the mat 26 .
- gypsum board in accordance with embodiments of the disclosure includes mats disposed on both the face side and the back side of the board.
- only the face mat is included in accordance with embodiments of the disclosure, while the back side of the board can have a conventional mat or paper facing material, or the back mat or paper can be absent (i.e., board is prepared without back cover sheet).
- the board can be used in indoor or outdoor applications where fluid (e.g., water or vapor) resistance is desired, e.g., for exterior sheathing, or the base for backsplashes, sink, shower, or bathtub enclosures, or other indoor surfaces in a high moisture area, on which a tile (e.g., ceramic) or other decorative surface is applied.
- a back mat is excluded.
- a suitable coating can be applied to the mat.
- the mat allows for the coating to penetrate into a portion, or certain level of thickness or volume of the mat, while discouraging the coating from penetrating all the way through the complete thickness of the mat and into the gypsum core.
- the coating applied to a wettable surface can spread substantially uniformly to form a thin coating on the outer surface of the mat that provides desired properties (e.g., one or more of mold resistance, water resistance, and fire resistance, etc.) in use. In accordance with preferred embodiments, this can be achieved by providing a mat with different regions exhibiting different properties or densities as described herein.
- the first region is more hydrophilic than the second region, on a comparative basis. In some embodiments, the first region has a lower comparative density than the second region. In some embodiments, the first region of the mat is more wettable than the second region. In some embodiments, the first region of the mat is more hydrophilic, wettable, and less dense than the second region. In this regard, the first region's hydrophilicity allows for good, even, and substantially uniform application of a desired coating to the outer surface of the mat, while the second region's hydrophobicity avoids the aqueous gypsum slurry from undesirably penetrating the mat to a high degree. Loose fibers in the mat bond to the slurry without excessive penetration of the slurry into the mat on the inner surface of the mat.
- the second region is denser and/or thicker than the first region.
- fibers in the mat can form a dense arrangement, creating a tortuous path for slurry to travel, thereby reducing the opportunity for stucco slurry to penetrate too deeply into the core interfacing the back mat, as desired.
- the first region in some embodiments is less dense than the second region, to allow for a less tortuous path for the coating being applied to the inner surface of the mat to penetrate the mat, while maintaining sufficient integrity (e.g., the first region is desirably not friable) under manufacturing or use conditions.
- the coating is able to penetrate and form a uniform layer that provides desired properties, including resistance to fluid, on the face side.
- the first region can have a basis weight of about 24 lb/MSF or less on a per area basis, while the second region can have a basis weight of about 29 lb/MSF or more.
- the second region has a basis weight that is at least 10% higher than the first region, e.g., at least about 15% higher, at least about 20% higher, at least about 25% higher, at least about 30% higher, at least about 35% higher, at least about 40% higher, at least about 45% higher, or at least about 50% higher, or even higher.
- the second region can have a basis weight that is from about 20% to about 50% higher than the basis weight of the first region, e.g., from about 20% to about 45% higher, from about 20% to about 40% higher, from about 20% to about 35% higher, from about 20% to about 30% higher, from about 20% to about 25% higher, from about 30% to about 50% higher, from about 30% to about 45% higher, from about 30% to about 40% higher, from about 35% to about 50% higher, from about 35% to about 45% higher, or from about 35% to about 40% higher.
- the first and second regions can be defined as being parallel to a horizontal plane of the mat and having certain thickness.
- Each of the first and second regions can have any suitable thickness.
- Preferably, each of the first and second regions has a substantial thickness.
- the mat can have any suitable total thickness, such as, for example, from about 0.015 inch to about 0.05 inch, e.g., from about 0.015 inch to about 0.045 inch, from about 0.015 inch to about 0.04 inch, from about 0.015 inch to about 0.035 inch, from about 0.015 inch to about 0.03 inch, from about 0.02 inch to about 0.05 inch, from about 0.02 inch to about 0.045 inch, from about 0.02 inch to about 0.04 inch, from about 0.02 inch to about 0.03 inch, from about 0.025 inch to about 0.05 inch, from about 0.025 inch to about 0.045 inch, from about 0.025 inch to about 0.04 inch, from about 0.025 inch to about 0.035 inch, from about 0.03 inch to about 0.05 inch, from about 0.03 inch
- the first region can contribute about 80% or less of the total thickness, such as, about 75%, about 70%, about 60%, about 50%, about 40%, about 30% or about 20% of the total thickness of the mat, e.g., from about 20% to about 80% of the total thickness, from about 20% to about 75%, from about 20% to about 75%, from about 20% to about 70%, from about 20% to about 60%, from about 20% to about 50%, from about 20% to about 40%, from about 20% to about 30%, from about 30% to about 80%, from about 30% to about 70%, from about 30% to about 60%, from about 30% to about 50%, from about 30% to about 40%, from about 40% to about 80%, from about 40% to about 75%, from about 40% to about 70%, from about 40% to about 60%, from about 40% to about 50%, from about 50% to about 80%, from about 50% to about 75%, from about 50% to about 70%, from about 50% to about 60%, from about 60% to about 80%, from about 60% to about 75%, from about 60% to about
- the second region can contribute about 80% or less of the total thickness, such as, about 75%, about 70%, about 60%, about 50%, about 40%, about 30% or about 20% of the total thickness of the mat, e.g., from about 20% to about 80% of the total thickness, from about 20% to about 75%, from about 20% to about 75%, from about 20% to about 70%, from about 20% to about 60%, from about 20% to about 50%, from about 20% to about 40%, from about 20% to about 30%, from about 30% to about 80%, from about 30% to about 70%, from about 30% to about 60%, from about 30% to about 50%, from about 30% to about 40%, from about 40% to about 80%, from about 40% to about 75%, from about 40% to about 70%, from about 40% to about 60%, from about 40% to about 50%, from about 50% to about 80%, from about 50% to about 75%, from about 50% to about 70%, from about 50% to about 60%, from about 60% to about 80%, from about 60% to about 75%, from about 60% to about 70%, from
- the second region is thicker than the first region is, e.g., at least about 10% thicker, at least about 15% thicker, at least about 20% thicker, at least about 25% thicker, at least about 30% thicker.
- the second region from about 10% to about 100% thicker than the first region, e.g., from about 10% to about 80% thicker, from about 10% to about 60% thicker, from about 10% to about 50% thicker, from about 10% to about 40% thicker, from about 10% to about 30% thicker, from about 20% to about 100% thicker, from about 20% to about 80% thicker, from about 20% to about 60% thicker, from about 20% to about 40% thicker, from about 20% to about 30% thicker, from about 30% to about 100% thicker, from about 30% to about 80% thicker, from about 30% to about 60% thicker, from about 30% to about 50% thicker, from about 30% to about 40% thicker, from about 40% to about 100% thicker, from about 40% to about 80% thicker, from about 40% to about 60% thicker, from about 30% to about 50% thicker, from about
- the coating is generally applied to the outer surface of the mat.
- the coating when dried penetrates from about 20% to about 80% of the total mat thickness.
- the coating when dried penetrates from about 20% to about 75% of the mat thickness, e.g., from about 20% to about 70%, from about 20% to about 60%, from about 20% to about 50%, from about 20% to about 40%, from about 20% to about 30%, from about 30% to about 80%, from about 30% to about 70%, from about 30% to about 60%, from about 30% to about 50%, from about 30% to about 40%, from about 40% to about 80%, from about 40% to about 75%, from about 40% to about 70%, from about 40% to about 60%, from about 40% to about 50%, from about 50% to about 80%, from about 50% to about 75%, from about 50% to about 70%, from about 50% to about 60%, from about 60% to about 80%, from about 60% to about 75%, from about 60% to about 70%, from about 80%, or from about 70% to about 75% of the total thickness of the mat
- the first region is more wettable than the second region. Wettability indicates the ability of a liquid to spread on a surface. A small contact angle results when the liquid spreads effectively for more wettable surfaces. Conversely, for less wettable surfaces, a larger contact angle is observed, compared with the first region.
- the second region has a high contact angle (e.g., above about 90°) and lower wettability as liquid minimizes contact with the surface and forms beads on the surface.
- the first region tends to have a low contact angle upon wetting with water.
- the first region has a higher surface energy than the second region.
- the first region can have a contact angle of about 90° or less, e.g., a contact angle of about 80° or less, about 70° or less, about 60° or less, about 50° or less, about 40° or less, about 30° or less, or about 20° or less.
- the first region can exhibit a contact angle of from about 0° to about 60°, e.g., from about 0° to about 55°, from about 0° to about 50°, from about 0° to about 45°, from about 0° to about 40°, from about 0° to about 30°, from about 0° to about 20°, from about 00 to about 10°, from about 10° to about 60°, from about 10° to about 55°, from about 100 to about 50°, from about 10° to about 45°, from about 10° to about 40°, from about 10° to about 30°, from about 10° to less than about 20°, from about 20° to about 60°, from about 20° to about 55°, from about 20° to about 50°, from about 20° to about 45°, from about 20° to about 40°, from about 20° to about 35°, from about 20° to about 30°, from about 30° to about 60°, from about 30° to about 55°, from about 30° to about 50°, from about
- the second region generally exhibits a higher contact angle, but the second region need not be hydrophobic, although in some embodiments it can be. In some embodiments, the second region can have a contact angle of about 600 or greater.
- the second region can have a contact angle of from about 600 to about 180°, e.g., from about from about 60° to about 150°, from about 60° to about 1200, from about 60° to about 100°, from about 60° to about 90°, from about 60° to about 80°, from about 60° to about 70°, from about 70° to about 180°, from about 70° to about 150°, from about 70° to about 120°, from about 70° to about 100°, from about 70° to about 90°, from about 70° to about 80°, from about 80° to about 180°, from about 80° to about 150°, from about 80° to about 120°, from about 80° to about 100°, from about 80° to about 900.
- a contact angle of from about 600 to about 180°, e.g., from about from about 60° to about 150°, from about 60° to about 1200, from about 60° to about 100°, from about 60° to about 90°, from about 60° to about 80°, from about 60° to about 70
- the second region is hydrophobic and has a contact angle over 90°.
- the second region has a contact angle of from about 90° to about 180°, from about 90° to about 170°, from about 90° to about 160°, from about 90° to about 150°, from about 90° to about 140°, from about 90° to about 130°, from about 90° to about 120°, from about 90° to about 110°, from about 90° to about 100°, from about 100° to about 180°, from about 100° to about 160°, from about 100° to about 140°, from about 100° to about 120°, from about 100° to about 110°, from about 120° to about 180°, from about 120° to about 150°, from about 120° to about 130°, from about 130° to about 180°, from about 130° to about 160°, from about 130° to about 150°, from about 140° to about 180°, from about 140° to about 160°, from about 150° to about 180°, from about 150° to about 180°, from about 150° to about 160°,
- the mat can be in the form of a multi-layer structure (e.g., a bi-layer structure).
- the mat can exhibit a gradient to form the two distinct regions of the mat (e.g., in a single layer).
- there can be a transition zone in between the first region and the second region e.g., where the transition zone has contribution of properties from both regions, with, for example, a less hydrophilic nature than the first region and/or a higher density than the first region, but with more of a hydrophilic nature than the second region and/or a lower density than the second region.
- the transition zone is a by-product of the manufacturing of the process.
- the porous fibrous mat is a glass fiber mat formed from chopped or continuous glass fibers having an average diameter of about 5 to about 20 microns, such as about 1° to about 20 microns or even about 11 to about 16 microns and a basis weight of about 20 lbs/1000 ft 2 or greater.
- the porous fibrous mat also can comprise microfibers having a diameter, for instance, of about 2-8 microns or 4-6 microns.
- the fibrous mat also can comprise fibers having different diameters.
- the glass fiber mat can comprise about 70 to about 90 percent glass fibers having a diameter of about 10 to about 20 microns and about 10 to about 30 percent glass fibers having a smaller diameter of about 2 to about 15 microns with a basis weight of about 20 lbs/1000 ft 2 or greater.
- the fibrous mat can comprise about 70 to about 90 percent glass fibers having a diameter of about 14 microns or greater, or 15 microns or greater (e.g., about 14 to about 16 microns) and about 10 to about 30 percent glass microfibers having a diameter of about 4 to about 6 microns with a basis weight of about 20 lbs/1000 ft 2 or greater.
- the fibers can have any suitable length.
- the microfibers can be of varying lengths.
- the other fibers typically will have a length of about 1-inch or less (e.g., about 3 ⁇ 8-inch to 1-inch, or about 1 ⁇ 2-inch to about 3 ⁇ 4-inch).
- one such glass fiber mat is formed from about 80 percent fibers having about 16 micron diameter (about 1 ⁇ 2 inch length) and about 20 percent of the fibers having about 11 micron diameter (about 1 ⁇ 4 inch length) with a basis weight of about 22 lbs/1000 ft 2 .
- Another suitable glass fiber mat is formed from about 90 percent fibers having about 16 micron diameter (3 ⁇ 4 inch length) and about 10 percent of the fibers having about 4 to about 6 micron diameter (various lengths) with a basis weight of about 22 lbs/1000 ft 2 .
- the mat comprises one or more binders in some embodiments.
- the mat is preferably formed using a thermosetting resin to bind the glass fibers into a non-woven web.
- the thermosetting resin may be an acrylic resin, such as a blend of melamine formaldehyde and other acrylic resins.
- the mat can comprise any suitable amount of binder, such as about 5-40% by weight, about 10-30% by weight, or about 20-30% by weight.
- the above described fibrous mat is but one example of a suitable mat that can be employed herein. It will be appreciated that other porous and fibrous mats having various compositions may also be employed using the methods described herein.
- the first region contains binder (optionally with additive) that contributes or imparts hydrophilicity to the first region.
- the second region contains binder with additive (e.g., a stearate compound) that contributes hydrophobicity to the second region.
- additive e.g., a stearate compound
- Increasing hydrophobicity can be achieved with increasing hydrocarbon chain lengths in, for example, one or more component of the binder composition.
- Increasing hydrophilicity can be achieved, for example, by selecting one or more binder component with reduced hydrocarbon chain length, and/or by making modifications to one or more components of the binder composition, such as by addition of hydroxyls in the chemical structure thereof.
- the first region contains a first binder that contributes or imparts hydrophilicity to the first region
- the second region contains a second binder that contributes or imparts hydrophobicity to the second region.
- the mat can be used with any suitable coating.
- a coating of hydrophobic resins can be applied to the face side of the mat.
- the coating can be an elastomeric membrane, e.g., ExoAir coatings (such as ExoAir 230 or 430), from Tremco, Beachwood, Ohio, or cement/polymer coatings, e.g., as described in U.S. Pat. No. 7,347,895 B2, or U.S. Pat. Pub. No. 2014/0272402 A1, or U.S. 2014/0261954 A1.
- the mat can be prepared in any suitable manner. For example, in a multi-layer design separate layer components can be prepared individually using known techniques including two layer wet felting or the like. The layers can then be bonded to each other along the horizontal surfaces thereof using known techniques including with adhesive, mechanical and/or heat pressing or the like. In some embodiments, the lower density first region is formed, and the higher density second region bonded on top thereof. In some embodiments, a gradient can be formed during wet felt mat formation through process manipulations including vacuum pressure or stock delivery. A coating is applied to the outer surface of the mat in a secondary step.
- Composite gypsum board according to embodiments of the disclosure can be made on typical gypsum wallboard manufacturing lines.
- board manufacturing techniques are described in, for example, U.S. Patent Pub. Nos. 2009/0029141 and 2010/0143682. Briefly, the process typically involves discharging a face mat onto a moving conveyor. Since gypsum board is normally formed “face down,” this mat is the “face” mat in such embodiments.
- stucco slurry also called gypsum slurry
- the stucco slurry is used to form the board core.
- the slurry contains water, stucco, and other additives as desired.
- Foaming agent or other lightweight material can be included in the core slurry to provide a lower density.
- additives can be included as desired, including, for example, starch for enhancing the strength of the board (e.g., non-migrating starches such as pregelatinized starch, ethoxylated starches, etc), dispersant (e.g., naphthalene sulfonate), polyphosphate (e.g., sodium trimetaphosphate), accelerator (e.g., heat resistant accelerator), retarder, water resistance additive (e.g., siloxane), fire resistance additive (e.g., vermiculite, ATH), etc.
- starch for enhancing the strength of the board
- dispersant e.g., naphthalene sulfonate
- polyphosphate e.g., sodium trimetaphosphate
- accelerator e.g., heat resistant accelerator
- retarder e.g., water resistance additive (e.g., siloxane), fire resistance additive (e.g., vermiculite, ATH), etc.
- the slurry can be formed in any suitable manner.
- the “main” mixer i.e., for forming the board core slurry
- the “main” mixer comprises a main body and a discharge conduit (e.g., a gate-canister-boot arrangement as known in the art, or a modified outlet design (MOD) arrangement as described in U.S. Pat. Nos. 6,494,609 and 6,874,930).
- Foaming agent can be added in the discharge conduit of the mixer (e.g., in the gate as described, for example, in U.S. Pat. Nos. 5,683,635 and 6,494,609) or in the main mixer.
- a dense layer can be applied in between the core and the face mat, and optionally between the core and the back mat.
- stucco and water are inserted into the main mixer, while foam is inserted downstream in the discharge conduit, meaning that foam is not inserted in the main mixer body.
- the main mixer can be a pin mixer or a pin-less mixer, as desired.
- a portion of the slurry, which is essentially foamless, is diverted from the mixer from an exit port generally opposite the discharge conduit to form the concentrated layer slurry.
- the main mixer acts as a pump to drive the unfoamed slurry out the smaller discharge port for the dense slurry which flows through the pressurized slurry line.
- Additives in wet form are injected into the pressurized slurry line through injection ports.
- the line is desirably long enough, which is within the level of ordinary skill, to allow for uniform mixing of slurry and additives. There is no need for separate introduction of stucco or water.
- two mixers can be used, with the second mixer for separately formulating a dense layer (skim coat), e.g., with less or no foam, to be deposited between the core and one or both mats.
- the discharge conduit can include a slurry distributor with either a single feed inlet or multiple feed inlets, such as those described in U.S. Patent Application Publication No. 2012/0168527 A1 (application Ser. No. 13/341,016) and U.S. Patent Application Publication No. 2012/0170403 A1 (application Ser. No. 13/341,209), for example.
- the discharge conduit can include a suitable flow splitter, such as those described in U.S. Patent Application Publication No. 2012/0170403 A1.
- Board is formed in a sandwich structure, normally concurrently and continuously, as will be understood in the art.
- the face mat travels on a conveyor.
- the dense layer slurry (skim coat) can optionally be applied to the moving face cover sheet to form a continuous ribbon.
- hard edges as known in the art, can be formed, e.g., from the same slurry stream forming the concentrated layer for convenience, if desired.
- the board core slurry is then applied over the moving face mat bearing the concentrated layer slurry, and covered with a second mat (typically the “back” mat) to form a wet assembly in the form of a sandwich structure that is a board precursor to the final product. It also is common in the manufacture of gypsum board to use vibration in order to eliminate large voids or air pockets from the deposited slurry.
- the back (top) mat may optionally bear a dense layer (skim coat).
- the wet assembly thereby provided is conveyed to a forming station where the product is sized to a desired thickness (e.g., via forming plate), and to one or more knife sections where it is cut to a desired length.
- the wet assembly is allowed to harden to form the interlocking crystalline matrix of set gypsum, and excess water is removed using a drying process (e.g., by transporting the assembly through a kiln).
- a mat for gypsum board comprising: (a) an outer surface and an inner surface; (b) a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first thickness, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second thickness; wherein: (i) the first region is more hydrophilic than the second region.
- a mat for gypsum board comprising: (a) an outer surface and an inner surface; (b) a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first thickness, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second thickness; wherein: (i) the first region is more wettable than the second region.
- a mat for gypsum board comprising: (a) an outer surface and an inner surface; (b) a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first thickness, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second thickness; wherein: (i) the first region is less dense than the second region.
- a gypsum board comprising: (a) a gypsum core disposed between two cover sheets; (b) the gypsum core comprising a crystalline matrix of set gypsum, the core having a face surface and a back surface; (c) one or both cover sheets being in the form of a mat; (d) a first mat having an outer surface and an inner surface, the first mat facing the face surface of the core, the first mat comprising a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first thickness, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second thickness, and optionally a second mat having an outer surface and an inner surface, the second mat facing the back surface of the core, the second mat comprising a third region adjacent to the outer surface of the second mat defined along a horizontal plane of the mat, the third region having a third thickness, and a fourth region adjacent to the inner surface defined along a horizontal plane of
- a gypsum board comprising: (a) a gypsum core disposed between two cover sheets; (b) the gypsum core comprising a crystalline matrix of set gypsum, the core having a face surface and a back surface; (c) one or both cover sheets being in the form of a mat; (d) a first mat having an outer surface and an inner surface, the first mat facing the face surface of the core, the first mat comprising a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first thickness, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second thickness, and optionally a second mat having an outer surface and an inner surface, the second mat facing the back surface of the core, the second mat comprising a third region adjacent to the outer surface of the second mat defined along a horizontal plane of the mat, the third region having a third thickness, and a fourth region adjacent to the inner surface defined along a horizontal plane of
- a gypsum board comprising: (a) a gypsum core disposed between two cover sheets; (b) the gypsum core comprising a crystalline matrix of set gypsum, the core having a face surface and a back surface; (c) one or both cover sheets being in the form of a mat; (d) a first mat having an outer surface and an inner surface, the first mat facing the face surface of the core, the first mat comprising a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first thickness, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second thickness, and optionally a second mat having an outer surface and an inner surface, the second mat facing the back surface of the core, the second mat comprising a third region adjacent to the outer surface of the second mat defined along a horizontal plane of the mat, the third region having a third thickness, and a fourth region adjacent to the inner surface defined along a horizontal plane of
- a method of making composite gypsum board comprising: (a) mixing at least water, stucco, and optionally one or more additives to form a slurry; (b) applying the slurry in a bonding relation to a face mat to form a board core, the board core having a face side and a back side, wherein the board core face side faces the face mat; (c) applying a back mat to the core slurry to form a board precursor; and (d) drying the board precursor to form the board; wherein: (i) at least one mat has an inner surface and an outer surface, and comprises a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first thickness, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second thickness; and (ii) the first region is more hydrophilic than the second region.
- a method of making composite gypsum board comprising: (a) mixing at least water, stucco, and optionally one or more additives to form a slurry; (b) applying the slurry in a bonding relation to a face mat to form a board core, the board core having a face side and a back side, wherein the board core face side faces the face mat; (c) applying a back mat to the core slurry to form a board precursor; and (d) drying the board precursor to form the board; wherein: (i) at least one mat has an inner surface and an outer surface, and comprises a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first thickness, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second thickness; and (ii) the first region is more wettable than the second region.
- a method of making composite gypsum board comprising: (a) mixing at least water, stucco, and optionally one or more additives to form a slurry; (b) applying the slurry in a bonding relation to a face mat to form a board core, the board core having a face side and a back side, wherein the board core face side faces the face mat; (c) applying a back mat to the core slurry to form a board precursor; and (d) drying the board precursor to form the board; wherein: (i) at least one mat has an inner surface and an outer surface, and comprises a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first thickness, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second thickness; and (ii) the first region is less dense than the second region.
- a method of preparing a mat for use as a cover sheet with board comprising: (a) introducing fibers to wet felting processing or the like to form a mat having an outer surface and an inner surface, the mat having a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first thickness, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second thickness; wherein (i) the first region is more hydrophilic than the second region.
- a method of preparing a mat for use as a cover sheet with board comprising: (a) introducing fibers to wet felting processing or the like to form a mat having an outer surface and an inner surface, the mat having a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first thickness, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second thickness; wherein (i) the first region is more wettable than the second region.
- a method of preparing a mat for use as a cover sheet with board comprising: (a) introducing fibers to wet felting processing or the like to form a mat having an outer surface and an inner surface, the mat having a first region adjacent to the outer surface defined along a horizontal plane of the mat, the first region having a first thickness, and a second region adjacent to the inner surface defined along a horizontal plane of the mat, the second region having a second thickness; wherein (i) the first region is less dense than the second region.
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- Civil Engineering (AREA)
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- Chemical & Material Sciences (AREA)
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JP2018555719A JP7053489B2 (ja) | 2016-05-13 | 2017-05-05 | マットを表面に有するボード、その製造方法 |
PCT/US2017/031181 WO2017196644A1 (en) | 2016-05-13 | 2017-05-05 | Mat-faced board and method for producing board |
CN201780024417.3A CN109089415A (zh) | 2016-05-13 | 2017-05-05 | 垫面层板和生产板的方法 |
MX2018012826A MX2018012826A (es) | 2016-05-13 | 2017-05-05 | Placa con revestimiento de manta y metodo para fabricar placas. |
AU2017262573A AU2017262573B2 (en) | 2016-05-13 | 2017-05-05 | Mat-faced board and method for producing board |
KR1020187034662A KR20190006507A (ko) | 2016-05-13 | 2017-05-05 | 매트-외장 보드 및 보드 제조 방법 |
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US10309771B2 (en) | 2015-06-11 | 2019-06-04 | United States Gypsum Company | System and method for determining facer surface smoothness |
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US10207475B2 (en) | 2019-02-19 |
JP7053489B2 (ja) | 2022-04-12 |
AU2017262573A1 (en) | 2018-12-20 |
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CN109089415A (zh) | 2018-12-25 |
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AU2017262573B2 (en) | 2021-12-02 |
CA3023885A1 (en) | 2017-11-16 |
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