This invention provides facing materials for cementitious boards such as those including Portland cement or gypsum cores. The preferred facing material includes, in a first embodiment, a facing layer having an areal weight of about 300 grams/M 2 , and an air permeability rating of no greater than about 300 CFM/ft 2 (FG 436-910 test method). The facing layer reduces the penetration of a slurry of cementitious material during the manufacture of a cementitious board, while permitting the water vapor from the slurry to pass therethrough. The facing materials of this invention can be designed to substantially eliminate the fouling of rolls used in continuous processing of such boards without the use, or with greatly reduced use, of costly viscosity control agents in the slurry. In addition, further embodiments of this invention can include binders, coatings or saturants which are designed to decrease pore size, increase or decrease the contact angle of liquids, or promote greater adhesion to cementitious cores, greater adhesion to other layers in the facing material, or greater adhesion or affinity to various types of adhesive compositions used to join cementitious boards to insulation and exterior finishing systems (EIS or EIFS).

Facing material with controlled porosity for construction boards

An improved dimensionally stable backing web is disclosed, especially for resilient flooring product and linoleum, comprising cellulosic fiber, a binder, antioxidant, fungicide and glass fiber, as well as optionally dyes or pigments, surfactants and vulcanizing agents. Also optionally present are calcium silicate mineral fiber or synthetic fiber, such as polyolefin, polyester, nylon, acrylic or modacrylic fiber, a cellulose acetate or mixtures thereof. The binder can be a natural rubber or synthetic rubber latex or mixtures thereof. The synthetic rubber latex is preferably selected from the following: styrene-butadiene; carboxylated styrene-butadiene, polyacrylic ester, polyvinyl acetate; polyisobutylene, a copolymer formed from vinyl acetate monomers and acrylic acid; polychloroprene, acrylonitrile-butadiene or carboxylated acrylonitrile-butadiene; polyurethane; a copolymer of ethylene and vinyl acetate; or other elastomeric copolymers. The glass fiber is dispersed into a slurry which is introduced in manufacturing the backing web by wet web impregnation, dry web impregnation, latex beater deposition, or continuous latex wet-end deposition, preferably by wet web impregnation. The web can be used alone or in combination with one or more surface coatings to form a layered material.

Dimensionally stable cellulosic backing web

A gypsum board which comprises a set gypsum core sandwiched between and faced with fibrous mats, wherein a free surface of one of said mats is pre-coated with a combination of a mineral pigment, optionally an inorganic adhesive binder and an organic binder, preferably a hydrophobic, UV resistant polymer latex adhesive binder applied to said surface as an aqueous coating composition, said aqueous coating composition upon drying and setting providing a pre-coated mat satisfying certain morphology requirements.

Use of pre-coated mat for preparing gypsum board

A siding panel product is provided comprising a first polymeric siding panel having a butt end and a top end, a front surface comprising a plurality of front faces defined between the top and butt ends and separated by at least one shoulder surface to define a stepped contour, and a rear surface. An insulation backing is coupled to the rear surface of the siding panel. The insulation backing comprises at least first and second insulation members coupled to the rear surface of said siding panel. The first insulation member has a bottom edge thereof coupled proximate to the stepped contour and the second insulation member has a top edge thereof coupled proximate to the stepped contour.

Moisture diverting insulated siding panel

A gypsum wallboard suitable for Level 4 finishing having a coated non-woven glass fiber mat facing material where the glass fiber mat has a majority of fibers of a fiber diameter between 8 and 11 microns and a fiber length between 1/4and3/4 inch and preferably between 1/4 and 1/2inch and preferably has a basis weight between about 0.8 lb./100 ft.2 and about 2.2 lb./100, and wherein the fibers in the non-woven glass fiber are bound together with an acrylic adhesive binder and wherein the non-woven glass mat has a coating of a dried aqueous mixture of (i) a mineral pigment, (ii) a polymer latex adhesive binder and optionally (iii) an inorganic adhesive binder such that the coated non-woven glass mat facing material has a porosity which allows water to evaporate through said coated mat from the gypsum core during preparation of the wallboard.

Interior wallboard and method of making same

In the process of manufacturing flat fibrous structures from suspensions of fibers by depositing a suspension of such fibers onto a moving permeable surface such as an endless sieve or belt wherein the fibrous suspension has been prepared from fibrous structures formed of a plurality of fibers which have been obtained by drawing a flowing glass melt, followed by chopping of the drawn fibers to form the fiber structures of predetermined length, the improvement in accordance with the invention of preparing the fiber suspension from fiber structures obtained by directing jets of liquid onto the glass fibers drawn from the glass melt and which are being wound onto the periphery of a rotating drum in a parallel arrangement and which after a certain layer thickness thereof has been obtained are cut to a predetermined length with the fibers still being in the moistened state.

Schuller W

Papers

Process for manufacturing endless fiber webs from inorganic fiber suspensions

Verfahren zur Herstellung einer endlosen Faserstoffbahn aus einer anorganischen Faseraufschwemmung