Georgia-pacific Gypsum, Inc.

Bpb Limited

Axalta Coating Systems IP Co LLC

Valspar Sourcing, Inc.

Bpb Limited, a U.k. Corporation

Christopher J Sanders

Yi-Hsien Harry Teng

Vincent B Thomas

Rochelle F Bradford

Robert J Hauber

Michael P Fahey

Mark E Hennis

Charles R Harrison

Martin L Gran

Mianxue Wu

Charles E Diller

Andrew W Tricker

Michael H Moore

Michael D Foster

James E Bailey

Herbert Dillard Temple

John E Kirkwood

Michael Deal

Jeffery T Fields

Gerald D Boydston

Herbert D Temple

Gypsum panels and methods for their manufacture are provided herein. The gypsum panels include a gypsum core having a first surface and a second opposed surface and a first fiberglass mat associated with the first surface of the gypsum core, such that gypsum from the gypsum core penetrates at least a portion of the first fiberglass mat.

Gypsum panels, systems, and methods

Gypsum panels, sheathing systems, and methods of making and using the same are provided. A gypsum panel includes a gypsum core associated with a first fiberglass mat having a continuous barrier coating, the coating penetrating a portion of the first fiberglass mat opposite the gypsum core, wherein gypsum penetrates a remaining fibrous portion of the first fiberglass mat such that voids in the first fiberglass mat are substantially eliminated. A building sheathing system includes at least two gypsum panels and a seaming component to provide a seam at an interface between the gypsum panels.

A method of forming a coating layer on a fibrous mat to make a coated article includes depositing a coating composition on a carrier material and at least partially embedding a first major surface of a fibrous mat in the coating composition, the fibrous mat including a plurality of mat fibers. The coating composition is at least partially hardened to form a coating layer at the first major surface of the fibrous mat. A second major surface of the fibrous mat opposite the first major surface includes an uncoated portion of the plurality of mat fibers.

Coated articles and methods for making the same

Hybrid nonwoven mats are made by depositing a slurry of fibers and water onto a fibrous web and applying a binder onto the hybrid nonwoven mat formed therefrom. The fibers are sized and present in an amount such that the binder forms a substantially continuous film on the hybrid nonwoven mat. Gypsum panels may be faced with a hybrid nonwoven mat on one or both surfaces.

Hybrid nonwoven mats and methods

Gypsum panels, panel cores, and methods for the manufacture thereof are provided herein. A gypsum panel core includes gypsum and fiberglass, the fiberglass being present in the core in an amount of from about 1 lb/msf to about 6 lb/msf. The core has a thickness of about 1/2 inch, a weight of from about 1400 lb/msf to about 1750 lb/msf, and an ASTM E-119 wood stud fire test rating of at least 30 minutes.

Gypsum panels, cores, and methods for the manufacture thereof

Gypsum panels, panel cores, and methods for the manufacture thereof are provided herein. A gypsum panel core includes gypsum and fiberglass, the fiberglass being present in the core in an amount of from about 1 lb/msf to about 6 lb/msf. The core has a thickness of about &#xbd; inch, a weight of from about 1400 lb/msf to about 1750 lb/msf, and an ASTM E-119 wood stud fire test rating of at least 30 minutes.

Gypsum board having inorganic fiber, preferably glass fiber, preferably glass fiber, includes providing face sheets which have been completely impregnated with a gypsum slurry so as to penetrate through said random interstices between the inorganic fibers and to thereby cover the board surfaces with gypsum slurry. The gypsum board product is formed by passing the wet gypsum board through a board forming station having double forming plates, an upper forming plate having at least a portion thereof being set at a predetermined angle relative to a lower forming plate and having a separation between the forming plates defining a predetermined dimension substantially equal to the desired thickness of the manufactured gypsum board product. The method provides a multilayer gypsum board having a polymeric compound added to unset gypsum so as to provide a gypsum board ready for finishing.

Method of manufacture of glass reinforced gypsum board and apparatus therefor

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Southaven, MS, United States of America

Christopher J Sanders