United States Gypsum Company

Mark B Scalf

Evan Vincent Rohlf

Christopher Robert Nelson

Alfred C Li

Christopher R Nelson

Michael J Porter

Michael Lawrence Bolind

Wei Xu

Dick C Engbrecht

David Song

A gypsum product with improved elasticity and increased nail-pull strength is provided, the product made with a glass fiber mat in which glass fibers are cross-linked with a polymeric resin. Further embodiments provide methods for making the glass fiber mats and gypsum products.

Gypsum products with improved glass fiber mat

Disclosed is an emulsion of an internal paper size and a biocidal emulsifying agent, such as a cationic non-starchy quaternary ammonium compounds, that is introduced into a paper-making furnish to produce an anti-microbial paper. The antimicrobial paper is useful as facing for gypsum panels. A method of making the paper includes emulsifying the internal size with a biocide before introducing the size to the paper furnish. A method of making a microbial growth resistant gypsum panel that incorporates the antimicrobial paper is also disclosed.

Antimicrobial size emulsion and gypsum panel made therewith

Disclosed is an emulsion of an internal paper size and a biocidal emulsifying agent, such as a cationic non-starchy quaternary ammonium compounds, that is introduced into a paper-making furnish to produce an antimicrobial paper. The antimicrobial paper is useful as facing for gypsum panels. A method of making the paper includes emulsifying the internal size with a biocide before introducing the size to the paper furnish. A method of making a microbial growth resistant gypsum panel that incorporates the antimicrobial paper is also disclosed.

The disclosed invention consists of an improved gypsum based, cellulosic containing board and method for applying a resin to an untreated board at a spray station where pMDI resin is sprayed onto the front and back side of the board. A resin distribution system is used to supply the spray nozzles with pMDI. Optionally, a second spray station is included, if desired, to add additional pMDI resin over the surface of the board to achieve complete coverage. The improvement is an increased water resistance and flexural strength.

Cellulose gypsum based substrate with increased water resistance and strength by surface application of polymeric diphenylmethane diisocyanate

Spray apparatus

The disclosed invention consists of a means for conveying a gypsum or gypsum/cellulose fiber board to a rotary cylinder brush station where pMDI resin is delivered onto the rotary cylinder brush just as the board passes under the brush. A resin distribution system is used to coat the rotary cylinder brush applicator with pMDI. Optionally, a second rotary cylinder brush station is included, if desired, to smooth out and spread the pMDI resin over the surface of the gypsum board substrate to achieve complete coverage.

Method for applying polymeric diphenylmethane diisocyanate to cellulose/gypsum based substrate

A process for reducing rollups in gypsum board panels when the panels are laminated with a laminate, is provided. A laminator is provided, as is at least one gypsum board panel, each panel having a face paper layer and a backing paper layer. Each paper layer has a coefficient of friction, and at least one of the face paper layer and the backing paper layer is treated with an agent for reducing the coefficient of friction and water absorbency. Next, a supply of laminate is provided and installed in the laminator. Then, at least one panel of the gypsum board is fed through the laminator, so that a layer of the laminate is applied thereon.

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McHenry, IL, United States of America

Mark B Scalf