Construction boards with improved facers
View Patent ↗A construction board ( 10 ) comprising a cellular body and at least one facer ( 22,23 ), where the at least one cellulosic facer ( 22,23 ) is characterized by a burst strength of at least 250 kPa pursuant to T403 om-02 (TAPPI).
1. A construction board comprising:
a cellular body; and
at least one cellulosic facer, where the at least one cellulosic facer is characterized by a burst strength of at least 250 kPa pursuant to T403 om-02 (TAPPI), where the at least one cellulosic facer is characterized by a basis weight of least 200 grams per square meter pursuant to T410 om-02 (TAPPI), where the at least one cellulosic facer has a thickness of from about 5 to about 20 mils, where the at least one cellulosic facer is characterized by a machine direction tensile strength pursuant to T494 om-01 (TAPPI) of at least 7.5 KN/m, and wherein the thickness of the at least one cellulosic facer is uniform within about ±3 mil.
2. The construction board of claim 1 , where the at least one cellulosic facer is characterized by a burst strength of at least 450 kPa pursuant to T403 om-02 (TAPPI), where the at least one cellulosic facer is characterized by a basis weight of least 300 grams per square meter T410 om-02 (TAPPI), where the at least one cellulosic facer has a thickness of less than about 15 mils, where the at least one cellulosic facer is characterized by a machine direction tensile strength pursuant to T494 om-01 (TAPPI) of at least 9.5 KN/m, and wherein the thickness of the at least one cellulosic facer is uniform within about ±1 mil.
3. The construction board of claim 1 , where the at least one cellulosic facer is substantially devoid of fiberglass.
4. The construction board of claim 1 , where the at least one cellulosic facer includes liner board.
5. The construction board of claim 1 , where the at least one cellulosic facer includes cellulosic fibers deriving from conifers.
6. The construction board of claim 1 , where the at least one cellulosic facer includes cellulosic fibers deriving from southern pines.
7. The construction board of claim 1 , where the at least one cellulosic facer includes cellulosic fibers that are fibrillated.
8. The construction board of claim 1 , where the at least one cellulosic facer includes cellulosic fibers deriving from virgin pulp, old corrugated containers, mixed office waste, and/or old newspaper.
9. The construction board of claim 1 , where the at least one facer has been heat treated at a temperature of from about 100 to about 120° F.
10. The construction board of claim 1 , where the cellular body is a closed-cell cellular structure.
11. The construction board of claim 1 , where the cellular body comprises polyisocyanurate.
12. The construction board of claim 1 , where the at least one cellulosic facer includes a pigment, mold inhibiting agents, or flame retardant.
13. The construction board of claim 1 , where the at least one cellulosic facer consists essentially of cellulosic fiber.
14. The construction board of claim 1 , where the at least one cellulosic facer consists essentially of cellulosic fiber and optionally pigments, mold-inhibiting agents, filler, and/or flame retardants.