Gypsum board and systems comprising it
View Patent ↗The invention relates to a new plasterboard having a facer comprising two plies, and uses of such plasterboards in EIS or EFS.
1. A gypsum board comprising at least one mat-facer and a gypsum core, wherein said at least one mat-facer comprises at least two nonwoven plies, an inner ply and an outer ply, where the inner ply is in contact with the core of said gypsum board and comprises a mixture of cellulose fibers, inorganic or mineral fibers and optionally organic fibers, and said outer piy comprises essentially cellulose fibers, wherein said mat-facer further comprises at least a binder and at least mineral filler particles, said particles being distributed at least partially into said inner ply or outer ply or both, wherein the mineral filler particles have a d 50 from about 0.1 to about 10 μm, and wherein the inner ply, the outer ply, or both the inner and outer plies further comprise a water-resistant agent.
2. The board of claim 1 , wherein said inorganic or mineral fibers are glass fibers.
3. The board of claim 1 , wherein said particles are distributed at least partially into both said inner ply and said outer ply.
4. The board of claim 1 , wherein said particles are distributed substantially fully into both said inner ply and said outer ply.
5. The board of claim 1 , wherein the inner ply comprises, by weight based on the total weight of the fibers, from 25 to 60 wt % of cellulose fibers, from 25 to 60 wt % of glass fibers, and from 0 to 30 wt % of organic fibers.
6. The board of claim 1 , wherein the inner ply comprises, by weight based on the total weight of the fibers, from 30 to 50 wt % of cellulose fibers, from 30 to 50 wt % of glass fibers, and from 10 to 20 wt % of organic fibers.
7. The board of claim 1 , wherein the inner and outer plies are bonded with first and second resinous binders, respectively, wherein the first and second resinous binders are the same.
8. The board of claim 1 , wherein the inner ply or the outer ply or both plies are bonded with a self cross-linkable binder or an hydrophobic binder or a mixture thereof.
9. The board of claim 1 , wherein the mineral filler particles have a d 50 from about 0.5 to about 5 μm.
10. The board of claim 1 , wherein the inner ply or the outer ply or both plies further comprises a water-resistant agent.
11. The board of claim 1 , wherein the inner ply or the outer ply or both plies further comprises a water-resistant agent which is a fluorocarbon repellent.
12. The board of claim 1 , wherein based on the final weight of the mat-facer, the inner ply represents from about 30 to about 150 g/m 2 , the outer ply represents from about 10 to about 70 g/m 2 , and the binder and filler together represent from about 20 to about 150 g/m 2 .
13. The board of claim 1 , wherein the weight ratio binder:filler is from about 1:2 to about 8:1.
14. The board of claim 1 , wherein the weight ratio binder:filler is from about 1:1 to about 4:1.
15. The board of claim 1 , wherein said board comprises two mat-facers.
16. The board of claim 1 , wherein the core comprises water-resistant additive in an amount sufficient such that the core absorbs less than about 10% water when tested in accordance with ASTM method C-473.
17. The board of claim 1 , wherein the core comprises water-resistant additive in an amount sufficient such that the core absorbs less than about 5% water when tested in accordance with ASTM method C-473.
18. The board of claim 1 , wherein the core comprises water-resistant additive in an amount sufficient such that the core absorbs less than about 3% water when tested in accordance with ASTM method C-473.
19. The board of claim 1 , wherein the core comprises fibers.
20. The board of claim 1 , wherein the core comprises fibers which are facer fibers or paper fibers.
21. The board of claim 1 , wherein the core comprises fibers which are from recycling.
22. The board of claim 1 , wherein the core comprises fire-resistant additive in an amount sufficient such that the board achieves an ASTM E-119 rating of at least about one hour.
23. The board of claim 1 , wherein the core comprises glass fibers in an amount from about 0.1% to about 1% of the core weight.
24. A gypsum board comprising at least one mat-facer and a gypsum core, wherein said at least one mat-facer comprises at least two nonwoven plies, an inner ply and an outer ply, where the inner ply is in contact with the core of said gypsum board and comprises a mixture of cellulose fibers, inorganic or mineral fibers and organic fibers, and said outer ply comprises essentially cellulose fibers, wherein said mat-facer further comprises at least a binder and at least mineral filler particles, said particles are distributed substantially fully into both said inner ply and said outer ply, and wherein the inner ply comprises, by weight based on the total weight of the fibers, from 30 to 50 wt % of cellulose fibers, from 30 to 50 wt % of glass fibers, and from 10 to 20 wt % of organic fibers, and wherein the inner ply, the outer ply, or both the inner and outer plies further comprise a water-resistant agent.
25. The board of claim 24 , wherein the inner and outer plies are bonded with first and second resinous binders, respectively, wherein the first and second resinous binders are the same resinous binder which is a self cross-linkable binder or an hydrophobic binder or a mixture thereof.
26. The board of claim 24 , wherein the mineral filler particles have a d 50 from about 0.5 to about 5 μm.
27. The board of claim 24 , wherein the inner and outer plies further comprise a water-resistant agent which is a fluorocarbon repellent.
28. The board of claim 24 , wherein based on the final weight of the mat-facer, the inner ply represents from about 30 to about 150 g/m 2 , the outer ply represents from about 10 to about 70 g/m 2 , and the binder and filler together represent from about 20 to about 150 g/m 2 .
29. The board of claim 24 , wherein the weight ratio binder:filler is from about 1:1 to about 4:1.
30. The board of claim 24 , wherein the core comprises water-resistant additive in an amount sufficient such that the core absorbs less than about 5% water when tested in accordance with ASTM method C-473.
31. The board of claim 24 , wherein the core comprises glass fibers in an amount from about 0.1% to about 1% of the core weight.
32. The board of claim 24 , wherein the core comprises fire-resistant additive in an amount sufficient such that the board achieves an ASTM E-119 rating of at least about one hour.
33. A gypsum board comprising at least one mat-facer and a gypsum core, wherein said at least one mat-facer comprises at least two nonwoven plies, an inner ply and an outer ply, and wherein the core comprises water-resistant additive in an amount sufficient such that the core absorbs less than about 10% water when tested in accordance with ASTM method C-473 and wherein the core comprises fire-resistant additive in an amount sufficient such that the board achieves an ASTM E-119 fire rating of at least about one hour, and wherein the inner ply, the outer ply, or both the inner and outer plies further comprise a water-resistant agent.
34. The board of claim 33 , wherein said mat-facer of the gypsum board comprises at least two plies, an inner ply and an outer ply, where the inner ply is in contact with the core of said gypsum board and comprises a mixture of cellulose fibers, inorganic or mineral fibers and optionally organic fibers, and said outer ply comprises essentially cellulose fibers.
35. The board of claim 33 , wherein the inner ply is in contact with the core of said gypsum board and comprises a mixture of cellulose fibers, inorganic or mineral fibers and optionally organic fibers, and said outer ply comprises essentially cellulose fibers, wherein said mat-facer further comprises at least a binder and at least mineral filler particles, said particles being distributed at least partially into said inner ply or outer ply or both plies.
36. The board of claim 34 , wherein said mat-facer of the gypsum board comprises at least two plies, an inner ply and an outer ply, where the inner ply is in contact with the core of said gypsum board and where said mat-facer comprises a fibrous nonwoven inner ply and an outer ply, said inner ply and said outer ply comprising fibers or particles or both, the fibers in the inner ply and the fibers or particles or both in the outer ply being bonded together with a same resinous binder.
37. The board of claim 36 , wherein in said mat-facer, the fibers or particles or both in the outer ply amount to about 0.5-20% by weight of the fibers in the inner ply of the mat-facer and wherein the fibers or particles or both in the outer ply are large enough that more than 99 percent of the particles or fibers or both are larger than the openings between the fibers in the inner ply.
38. An exterior insulation system for a building comprising a mat-facer gypsum board comprising at least one mat-facer and a gypsum core, insulating material having an inner surface and an outer surface, the inner surface of which is adhered to the surface of the mat-facer of said gypsum board by an adhesive material, and an exterior finishing material overlying the outer surface of said insulating material, wherein said mat-facer of the gypsum board comprises at least two nonwoven plies, an inner ply and an outer ply, where the inner ply is in contact with the core of said gypsum board and comprises a mixture of cellulose fibers, inorganic or mineral fibers and optionally organic fibers, and said outer ply comprises essentially cellulose fibers, and wherein the inner ply, the outer ply, or both the inner and outer plies further comprise a water-resistant agent.
39. An exterior insulation system for a building comprising a mat-facer gypsum board comprising at least one mat-facer and a gypsum core, insulating material having an inner surface and an outer surface, the inner surface of which is adhered to the surface of the mat-facer of said gypsum board by an adhesive material, and an exterior finishing material overlying the outer surface of said insulating material, wherein said mat-facer of the gypsum board comprises at least two nonwoven plies, an inner ply and an outer ply, where the inner ply is in contact with the core of said gypsum board and where said mat-facer comprises a fibrous nonwoven inner ply and an outer ply, said inner ply and said outer ply comprising fibers or particles or both, the fibers in the inner ply and the fibers or particles or both in the outer ply being bonded together with a same resinous binder, and wherein the inner ply, the outer ply, or both the inner and outer plies further comprise a water-resistant agent.
40. The system of claim 39 , wherein in said mat-facer, the fibers or particles or both in the outer ply amount to about 0.5-20% by weight of the fibers in the inner ply of the mat-facer and wherein the fibers or particles or both in the outer ply are large enough that more than 99 percent of the particles or fibers or both are larger than the openings between the fibers in the inner ply.
41. The system of claim 38 , including a reinforcing member sandwiched between said insulating material and said finishing material.
42. The system of claim 39 , including a reinforcing member sandwiched between said insulating material and said finishing material.
43. An exterior finishing system for a building comprising an underlying structural support element which is covered with an overlying finishing material, said support element including mat-facer gypsum board comprising a set gypsum core sandwiched between two sheets of facers, the gypsum core including water-resistant additives in an amount at least sufficient to impart to the core improved water-resistant properties, wherein said mat-facer of the gypsum board comprises at least two nonwoven plies, an inner ply and an outer ply, where the inner ply is in contact with the core of said gypsum board and comprises a mixture of cellulose fibers, glass fibers and optionally organic fibers, and said outer ply comprises essentially cellulose fibers, and wherein the inner ply, the outer ply, or both the inner and outer plies further comprise a water-resistant agent.
44. An exterior finishing system for a building comprising an underlying structural support element which is covered with an overlying finishing material, said support element including mat-facer gypsum board comprising a set gypsum core sandwiched between two sheets of facers, the gypsum core including water-resistant additives in an amount at least sufficient to impart to the core improved water-resistant properties, wherein said mat-facer of the gypsum board comprises at least two nonwoven plies, an inner ply and an outer ply, where the inner ply is in contact with the core of said gypsum board and where said mat-facer comprises a fibrous nonwoven inner ply and an outer ply, said inner ply and said outer piy comprising fibers or particles or both, the fibers in the inner ply and the fibers or particles or both in the outer ply being bonded together with first and second resinous binders, respectively, wherein the first and second resinous binders are the same, and wherein the inner ply, the outer ply, or both the inner and outer plies further comprise a water-resistant agent.
45. The system of claim 44 , wherein in said mat-facer, the fibers or particles or both in the outer ply amount to about 0.5-20% by weight of the fibers in the inner ply of the mat-facer and wherein the fibers or particles or both in the outer ply are large enough that more than 99 percent of the particles or fibers or both are larger than the openings between the fibers in the inner ply.
46. An internal wet or humid area partition assembly system comprising metal or wood framework or studs for support of a board, said board including a mat-facer gypsum board comprising a set gypsum core sandwiched between two sheets of facers, the gypsum core including water-resistant additives in an amount at least sufficient to impart to the core improved water-resistant properties, wherein said mat-facer of the gypsum board comprises at least two nonwoven plies, an inner ply and an outer ply, where the inner ply is in contact with the core of said gypsum board and comprises a mixture of cellulose fibers, inorganic or mineral fibers and optionally organic fibers, and said outer ply comprises essentially cellulose fibers, and wherein the inner ply, the outer ply, or both the inner and outer plies further comprise a water-resistant agent.
47. An internal wet or humid area partition assembly system comprising metal or wood framework or studs for support of a board, said board including a mat-facer gypsum board comprising a set gypsum core sandwiched between two sheets of facers, the gypsum core including water-resistant additives in an amount at least sufficient to impart to the core improved water-resistant properties, wherein said mat-facer of the gypsum board comprises at least two nonwoven plies, an inner ply and an outer ply, where the inner ply is in contact with the core of said gypsum board and where said mat-facer comprises a fibrous nonwoven inner ply and an outer ply, said inner ply and said outer ply comprising fibers or particles or both, the fibers in the inner ply and the fibers or particles or both in the outer piy being bonded together with first and second resinous binders, respectively, wherein the first and second resinous binders are the same, and wherein the inner ply, the outer ply, or both the inner and outer plies further comprise a water-resistant agent.
48. The system of claim 47 , wherein in said mat-facer, the fibers or particles or both in the outer ply amount to about 0.5-20% by weight of the fibers in the inner ply of the mat-facer and wherein the fibers or particles or both in the outer ply are large enough that more than 99 percent of the particles or fibers or both are larger than the openings between the fibers in the inner ply.
49. The system of claim 38 , wherein the inner ply comprises, by weight based on the total weight of the fibers, from 30 to 50 wt % of cellulose fibers, from 30 to 50 wt % of glass fibers, and from 10 to 20 wt % of organic fibers.
50. The system of claim 38 , wherein the inner and outer plies are bonded with the same resinous binder which is a self cross-linkable binder or an hydrophobic binder or a mixture thereof.
51. The system of claim 38 , wherein the mineral filler particles have a d 50 from about 0.5 to about 5 μm.
52. The system of claim 38 , wherein the inner and outer plies further comprise a water-resistant agent which is a fluorocarbon repellent.
53. The system of claim 38 , wherein based on the final weight of the mat-facer, the inner ply represents from about 30 to about 150 g/m 2 , the outer ply represents from about 10 to about 70 g/m 2 , and the binder and filler together represent from about 20 to about 150 g/m 2 .
54. The system of claim 38 , wherein the weight ratio binder:filler is from about 1:1 to about 4:1.
55. The system of claim 38 , wherein the core comprises water-resistant additive in an amount sufficient such that the core absorbs less than about 5% water when tested in accordance with ASTM method C-473.
56. The system of claim 38 , wherein the core comprises glass fibers in an amount from about 0.1% to about 1% of the core weight.
57. The system of claim 38 , wherein the core comprises fire-resistant additive in an amount sufficient such that the board achieves an ASTM E-119 rating of at least about one hour.
58. The system of claim 38 , wherein the board is according to claim 1 .
59. The system of claim 38 , wherein the board is according to claim 24 .
60. The system of claim 39 , wherein the inner ply comprises, by weight based on the total weight of the fibers, from 30 to 50 wt % of cellulose fibers, from 30 to 50 wt % of glass fibers, and from 10 to 20 wt % of organic fibers.
61. The system of claim 39 , wherein the inner and outer plies are bonded with the same resinous binder which is a self cross-linkable binder or an hydrophobic binder or a mixture thereof.
62. The system of claim 39 , wherein the mineral filler particles have a d 50 from about 0.5 to about 5 μm.
63. The system of claim 39 , wherein the inner and outer plies further comprise a water-resistant agent which is a fluorocarbon repellent.
64. The system of claim 39 , wherein based on the final weight of the mat-facer, the inner ply represents from about 30 to about 150 g/m 2 , the outer ply represents from about 10 to about 70 g/m 2 , and the binder and filler together represent from about 20 to about 150 g/m 2 .
65. The system of claim 39 , wherein the weight ratio binder:filler is from about 1:1 to about 4:1.
66. The system of claim 39 , wherein the core comprises water-resistant additive in an amount sufficient such that the core absorbs less than about 5% water when tested in accordance with ASTM method C-473.
67. The system of claim 39 , wherein the core comprises glass fibers in an amount from about 0.1% to about 1% of the core weight.
68. The system of claim 39 , wherein the core comprises fire-resistant additive in an amount sufficient such that the board achieves an ASTM E-119 rating of at least about one hour.
69. The system of claim 39 , wherein the board is according to claim 1 .
70. The system of claim 39 , wherein the board is according to claim 24 .
71. The system of claim 43 , wherein the inner ply comprises, by weight based on the total weight of the fibers, from 30 to 50 wt % of cellulose fibers, from 30 to 50 wt % of glass fibers, and from 10 to 20 wt % of organic fibers.
72. The system of claim 43 , wherein the inner and outer plies are bonded with the same resinous binder which is a self cross-linkable binder or an hydrophobic binder or a mixture thereof.
73. The system of claim 43 , wherein the mineral filler particles have a d 50 from about 0.5 to about 5 μm.
74. The system of claim 43 , wherein the inner and outer plies further comprise a water-resistant agent which is a fluorocarbon repellent.
75. The system of claim 43 , wherein based on the final weight of the mat-facer, the inner ply represents from about 30 to about 150 g/m 2 , the outer ply represents from about 10 to about 70 g/m 2 , and the binder and filler together represent from about 20 to about 150 g/m 2 .
76. The system of claim 43 , wherein the weight ratio binder:filler is from about 1:1 to about 4:1.
77. The system of claim 43 , wherein the core comprises water-resistant additive in an amount sufficient such that the core absorbs less than about 5% water when tested in accordance with ASTM method C-473.
78. The system of claim 43 , wherein the core comprises glass fibers in an amount from about 0.1% to about 1% of the core weight.
79. The system of claim 43 , wherein the core comprises fire-resistant additive in an amount sufficient such that the board achieves an ASTM E-119 rating of at least about one hour.
80. The system of claim 43 , wherein the board is according to claim 1 .
81. The system of claim 43 , wherein the board is according to claim 24 .
82. The system of claim 44 , wherein the inner ply comprises, by weight based on the total weight of the fibers, from 30 to 50 wt % of cellulose fibers, from 30 to 50 wt % of glass fibers, and from 10 to 20 wt % of organic fibers.
83. The system of claim 44 , wherein the inner and outer plies are bonded with the same resinous binder which is a self cross-linkable binder or an hydrophobic binder or a mixture thereof.
84. The system of claim 44 , wherein the mineral filler particles have a d 50 from about 0.5 to about 5 μm.
85. The system of claim 44 , wherein the inner and outer plies further comprise a water-resistant agent which is a fluorocarbon repellent.
86. The system of claim 44 , wherein based on the final weight of the mat-facer, the inner ply represents from about 30 to about 150 g/m 2 , the outer ply represents from about 10 to about 70 g/m 2 , and the binder and filler together represent from about 20 to about 150 g/m 2 .
87. The system of claim 44 , wherein the weight ratio binder:filler is from about 1:1 to about 4:1.
88. The system of claim 44 , wherein the core comprises water-resistant additive in an amount sufficient such that the core absorbs less than about 5% water when tested in accordance with ASTM method C-473.
89. The system of claim 44 , wherein the core comprises glass fibers in an amount from about 0.1% to about 1% of the core weight.
90. The system of claim 44 , wherein the core comprises fire-resistant additive in an amount sufficient such that the board achieves an ASTM E-119 rating of at least about one hour.
91. The system of claim 44 , wherein the board is according to claim 1 .
92. The system of claim 44 , wherein the board is according to claim 24 .
93. The system of claim 46 , wherein the inner ply comprises, by weight based on the total weight of the fibers, from 30 to 50 wt % of cellulose fibers, from 30 to 50 wt % of glass fibers, and from 10 to 20 wt % of organic fibers.
94. The system of claim 46 , wherein the inner and outer plies are bonded with the same resinous binder which is a self cross-linkable binder or an hydrophobic binder or a mixture thereof.
95. The system of claim 46 , wherein the mineral filler particles have a d 50 from about 0.5 to about 5 μm.
96. The system of claim 46 , wherein the inner and outer plies further comprise a water-resistant agent which is a fluorocarbon repellent.
97. The system of claim 46 , wherein based on the final weight of the mat-facer, the inner ply represents from about 30 to about 150 g/m 2 , the outer ply represents from about 10 to about 70 g/m 2 , and the binder and filler together represent from about 20 to about 150 g/m 2 .
98. The system of claim 46 , wherein the weight ratio binder:filler is from about 1:1 to about 4:1.
99. The system of claim 46 , wherein the core comprises water-resistant additive in an amount sufficient such that the core absorbs less than about 5% water when tested in accordance with ASTM method C-473.
100. The system of claim 46 , wherein the core comprises glass fibers in an amount from about 0.1% to about 1% of the core weight.
101. The system of claim 46 , wherein the core comprises fire-resistant additive in an amount sufficient such that the board achieves an ASTM E-119 rating of at least about one hour.
102. The system of claim 46 , wherein the board is according to claim 1 .
103. The system of claim 46 , wherein the board is according to claim 24 .
104. The system of claim 47 , wherein the inner ply comprises, by weight based on the total weight of the fibers, from 30 to 50 wt % of cellulose fibers, from 30 to 50 wt % of glass fibers, and from 10 to 20 wt % of organic fibers.
105. The system of claim 47 , wherein the inner and outer plies are bonded with the same resinous binder which is a self cross-linkable binder or an hydrophobic binder or a mixture thereof.
106. The system of claim 47 , wherein the mineral filler particles have a d 50 from about 0.5 to about 5 μm.
107. The system of claim 47 , wherein the inner and outer plies further comprise a water-resistant agent which is a fluorocarbon repellent.
108. The system of claim 47 , wherein based on the final weight of the mat-facer, the inner ply represents from about 30 to about 150 g/m 2 , the outer ply represents from about 10 to about 70 g/m 2 , and the binder and filler together represent from about 20 to about 150 g/m 2 .
109. The system of claim 47 , wherein the weight ratio binder:filler is from about 1:1 to about 4:1.
110. The system of claim 47 , wherein the core comprises water-resistant additive in an amount sufficient such that the core absorbs less than about 5% water when tested in accordance with ASTM method C-473.
111. The system of claim 47 , wherein the core comprises glass fibers in an amount from about 0.1% to about 1% of the core weight.
112. The system of claim 47 , wherein the core comprises fire-resistant additive in an amount sufficient such that the board achieves an ASTM E-119 rating of at least about one hour.
113. The system of claim 47 , wherein the board is according to claim 1 .
114. The system of claim 47 , wherein the board is according to claim 24 .
115. A shaft wall assembly comprising a board according to claim 1 .
116. A shaft wall assembly comprising a board according to claim 24 .
117. An exterior finishing system comprising a board according to claim 1 .
118. An exterior finishing system comprising a board according to claim 24 .
119. An exterior insulation system comprising a board according to claim 1 .
120. An exterior insulation system comprising a board according to claim 24 .
121. Tile backing comprising a board according to claim 1 .
122. Tile backing comprising a board according to claim 24 .
123. Partitions and ceilings in wet area rooms comprising a board according to claim 1 .
124. Partitions and ceilings in wet area rooms comprising a board according to claim 24 .
125. The board of claim 1 , wherein said nonwoven plies are wet laid nonwoven plies.