Nonwoven Glass Mat with Dissolvable Binder System For Fiber-Reinforced Gypsum Board
A gypsum board was patented. The board includes a gypsum matrix provided from an aqueous gypsum slurry and has a bottom and a top, a centerline, and external surfaces. A first facer sheet is placed on the bottom of the gypsum matrix. A second facer sheet is placed on the top of the gypsum matrix. One or more sizing coated nonwoven glass fiber mats is placed at preselected locations within the gypsum matrix. The sizing coated non-woven glass fiber mats are bonded by a dissolvable or reversible binder that secures the glass fiber mats in a preselected fiber architecture during handling of the glass fiber mats. The dissolvable or reversible binder dissolves in the aqueous gypsum slurry or reverses during gypsum board drying thereby creating intimate contact between sizing coated glass fibers in the nonwoven glass fiber mat and the gypsum matrix. This arrangement provides reinforcement to the gypsum board.