[특허]Non-woven glass mat with dissolvable binder system for fiber-reinforced gypsum board

[미국특허] Non-woven glass mat with dissolvable binder system for fiber-reinforced gypsum board 원문보기

IPC분류정보
국가/구분	United States(US) Patent 등록
국제특허분류(IPC7판)	B32B-017/12 B32B-013/10 B32B-013/00
출원번호	US-0832500 (2004-04-27)
등록번호	US-7338702 (2008-03-04)
발명자 / 주소	Swales,Timothy G. Scheerlinck,Philippe M.
출원인 / 주소	Johns Manville
대리인 / 주소	Touslee,Robert D.
인용정보	피인용 횟수 : 14 인용 특허 : 13

초록 ▼

A gypsum board having glass fiber reinforcement. The glass fiber has sizing promoting bonding with a gypsum matrix. The glass fibers are added to the gypsum matrix cia a non-woven glass fiber mat bonded initially with a dissolvable or reversible binder to maintain the three dimensional architecture of the non-woven glass fiber mat during handling and insertion into a cast wet gypsum slurry forming a gypsum board. Upon insertion in the wet gypsum slurry, the dissolvable bond between the glass fibers in the non-woven glass fiber mat dissolves and allows the sizing coating on the glass fibers to make intimate contact with the gypsum matrix. In case of the reversible bond, the bond adhesive hydrolyzes during the gypsum board drying cycle providing intimate contact between the sizing coated glass fibers and the gypsum matrix. The non-woven glass fiber mats bonded to the gypsum matrix provides improved strength and flexure resistance of the gypsum board.

대표청구항 ▼

What is claimed is: 1. A gypsum board, comprising: a. a gypsum matrix provided from an aqueous gypsum slurry and having a bottom and a top, a centerline, and external surfaces; b. a first facer sheet placed on said bottom of said gypsum matrix; c. a second facer sheet placed on said top of said gypsum matrix; d. one or more sizing coated non-woven glass fiber mats placed at preselected locations within said gypsum matrix; and e. said sizing coated non-woven glass fiber mats bonded by a dissolvable or reversible binder that secure said glass fiber mats in a preselected fiber architecture during handling of said glass fiber mats, whereby said dissolvable or reversible binder dissolves in said aqueous gypsum slurry or reverses during gypsum board drying thereby creating intimate contact between sizing coated glass fibers in said non-woven glass fiber mat and said gypsum matrix providing reinforcement to said gypsum board. 2. A gypsum board as recited by claim 1, wherein each of said first and said second facer sheets comprises Kraft paper. 3. A gypsum board as recited by claim 1, wherein said aqueous gypsum slurry is made by mixing at least one member selected from the group consisting of calcium sulphate hemihydrate (CaSO4.1/2H2O), calcium sulphate anhydrite (CaSO4), hydraulic setting cement and water. 4. A gypsum board as recited by claim 1 wherein said sizing coating on glass fibers is silane based. 5. A gypsum board as recited by claim 1 wherein said sizing coating on glass fibers comprises polymethylsiloxane which is cured at 100-150�� C. 6. A gypsum board as recited by claim 1 wherein said dissolvable or reversible binder comprises starch. 7. A gypsum board as recited by claim 1 wherein said dissolvable or reversible binder comprises casein glue. 8. A gypsum board as recited by claim 1 wherein said dissolvable or reversible binder comprises polyvinyl alcohol. 9. A gypsum board as recited by claim 1 wherein said non-woven glass fiber mat has a density ranging from 0.5 lb/100 square feet (square is 100 square foot) to 5.0 lb/100 square feet. 10. A gypsum board as recited by claim 1 wherein said non-woven fiber mats are placed away from said centerline of said gypsum matrix and do not touch said external surfaces of said gypsum matrix having on said top and said bottom a first facer and a second facer, respectively.

이 특허에 인용된 특허 (13) 인용/피인용 타임라인 분석

Green George W. (Stone Mountain GA) Randall Brian G. (Stone Mountain GA), Coated fibrous mat faced gypsum board resistant to water and humidity.
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Takahashi Kazuhiro,JPX, Decorated sheet.
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Lehnert Charles W. (Stone Mountain GA) Randall Brian G. (Stone Mountain GA), Fibrous mat-faced gypsum board.
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Schoenky John H. (22700 NW. Quatama St. Hillsboro OR 97124), Flanged pipe support.
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Turpin Kenneth A.,CAX ; Versen Richard A. ; Burdic Bradley ; Larson Reed H. ; Shumate Monroe W., Gypsum board/intumescent material fire barrier wall.
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Dierks Robert P. (Des Plaines IL) Rillie Robert J. (Des Plaines IL), Gypsum wallboard and process for making same.
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Koval, Francis J.; Neal, David J.; Silversides, Richard; Riccio, Jr., Joseph; Raymond, Charles J.; Cummins, Felmer F., Interior wallboard and method of making same.
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Jobbins Richard M., Lightweight gypsum composition.
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Bush,Philip; Blanpied,Robert H.; Murphy,Freddie Lee; Dubose,Jimmy Rogers, Method and composition for coating mat and articles produced therewith.
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Sellers Dwight G. (Fort Dodge IA) Altman Franklin A. (Hortense GA) Richards Turner W. (Conyers GA), Method of manufacturing a water-resistant gypsum composition.
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Randall, Brian G.; Ricards, Gary A., Pre-coated mat-faced gypsum board.
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Kono Yoshimi (Amagasaki JPX) Maeda Sabee (Osaka JPX), Thermosetting resin composition.
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Chase Kenneth P. (Newark OH) Stassen William N. (Newark OH), Water soluble sizing for glass fibers and glass fibers sized therewith.
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이 특허를 인용한 특허 (14) 인용/피인용 타임라인 분석

Liu, Qingxia; Shake, Michael P.; Yu, Qiang, Cementitious article and method for preparing the same.
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Lyons, David; Sukkar, Theresa, Composite cement article incorporating a powder coating and methods of making same.
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Rottiers, Alex; Weyers, Tom; Mees, Stephan, Construction element for use in interior decoration.
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Naji, Basil; Merkley, Donald J.; Zammit, Michael; Luo, Caidian, Durable medium-density fibre cement composite.
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Gleeson, James A.; Paradis, Kalynne H.; Sloane, Brian P.; Melmeth, David L.; Seligman, Dean M., Fiber cement building materials with low density additives.
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Gleeson, James A.; Paradis, Kalynne H.; Sloane, Brian P.; Melmeth, David L.; Seligman, Dean M., Fiber cement building materials with low density additives.
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Gleeson, James A.; Paradis, Kalynne H.; Sloane, Brian P.; Melmeth, David L.; Seligman, Dean M., Fiber cement building materials with low density additives.
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Gleeson, James A.; Paradis, Kalynne H.; Sloane, Brian P.; Melmeth, David L.; Seligman, Dean M., Fiber cement building materials with low density additives.
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Paradis, Duane; Zheng, Guodong, Fire resistant composite boards and methods.
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Alexander, Glenn David; Salpietra, Jr., Joseph Anthony, Flame resistant filter apparatus and method.
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Alexander, Glenn David; Salpietra, Joseph Anthony, Flame resistant viscose filter apparatus and method.
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Alexander, Glenn David; Salpietra, Jr., Joseph Anthony, Grease removal apparatus, systems and methods.
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Duselis, Steven Alfred; Gleeson, James; Kascelan, Tihomir; Lyons, David; O'Chee, Milton Terrence, Surface sealed reinforced building element.
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Engbrecht, Dick C.; Liu, Qingxia; Shake, Michael P.; Wang, Xuming; Miller, David Paul; Bolind, Michael L.; Reed, Paul; Roelfs, Donald L.; Bury, Rafael, Water resistant cementitious article and method for preparing same.
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[미국특허] Non-woven glass mat with dissolvable binder system for fiber-reinforced gypsum board 원문보기