Abstract: An underlayment for supplementing one or more mechanical properties of conventional wall, ceiling, or floor board is used to in a wall, ceiling, or floor assembly that may be fabricated on site. The assembly includes a first and second wall, ceiling, or floor boards which each have mechanical properties, and the underlayment which has at least one supplemental mechanical property for supplementing the physical properties of the first and second boards. The second board is secured to the first board with the underlayment sandwiched between the second and first boards to form a wall, ceiling, or floor assembly with the supplemental physical property or properties of the underlayment. The supplemental physical property or properties of the underlayment may include, but are not limited to, sound transmission reduction.

Abstract: A gypsum board includes a set gypsum core and front and rear paper facers adhered thereto. At least the front paper facer has substantially isotropic tensile strength, thereby providing the gypsum board with enhanced nail pull resistance. A process for manufacturing such gypsum board is further provided.

Abstract: A method for producing a reinforced polyester non-woven material suitable for use as a roofing material, comprising: forming a mixture comprising glass fibers and a liquid binder; applying the mixture to a polyester non-woven material; and curing the liquid binder to form a layer comprising glass fibers that is attached to the polyester non-woven material.

Abstract: Fibrous, nonwoven mats are disclosed that are bound with a formaldehyde-free, heat resistant resin in direct contact with the fibers. The heat resistant resin is capable of withstanding coating with a hot, molten material like asphalt or a mixture containing asphalt having a temperature of at least about 300 degrees F. and up to 450 degrees F. or higher. The preferred heat resistant resins are epoxies and urethanes, or mixtures thereof. The methods of making these mats with wet processes are also disclosed.

Abstract: A gypsum board having glass fiber reinforcement. The glass fiber has sizing promoting bonding with a gypsum matrix. The glass fibers are added to the gypsum matrix cia a non-woven glass fiber mat bonded initially with a dissolvable or reversible binder to maintain the three dimensional architecture of the non-woven glass fiber mat during handling and insertion into a cast wet gypsum slurry forming a gypsum board. Upon insertion in the wet gypsum slurry, the dissolvable bond between the glass fibers in the non-woven glass fiber mat dissolves and allows the sizing coating on the glass fibers to make intimate contact with the gypsum matrix. In case of the reversible bond, the bond adhesive hydrolyzes during the gypsum board drying cycle providing intimate contact between the sizing coated glass fibers and the gypsum matrix. The non-woven glass fiber mats bonded to the gypsum matrix provides improved strength and flexure resistance of the gypsum board.

Abstract: A gypsum board having roughened surface glass fiber reinforcement. The roughened surface of glass fiber is created by incorporating nano or micro particles of colloidal silica or clay or other inorganic particles in a silane based sizing composition. The sizing coating is partially or completely cured and incorporated in gypsum wet mix either as additions of chopped fibers or as placement of roughened surface glass fiber mats at selected locations within a cast gypsum sheet. The roughened surface of glass fiber with nano or micro particles compliantly bonded with silane polymer transfers load from gypsum to glass fibers providing improved strength and flexure resistance of gypsum boards.