Abstract: A bond is created during gypsum board cure between a gypsum matrix and a tacky coating applied onto a glass fiber. The tacky coating is comprised of a polymer composed of methacrylic acid and dimethyldiallyammonium chloride. The polymer is dissolved in an acidic aqueous solution and is roller coated onto the glass fibers. The chopped glass fibers may also be placed in such an acidic solution, which is made alkaline by the addition of alkali, thereby precipitating the polymer out of solution as a tacky composition that produces a tacky coating on the glass fibers. The glass fibers with the tacky bond coating are incorporated in an alkaline gypsum slurry to form a gypsum board having a first and second facer sheet. The tacky coating on the glass fibers bonded to the gypsum matrix result in compliant load transfer between the gypsum matrix and the glass fibers, yielding improved flexure strength and nail pullout resistance.

Abstract: The invention is an improved method for manufacturing fiberglass. In the method of the invention, traditional raw materials are at least partially replaced by pre-reacted materials. Use of these pre-reacted material results is less energy based to manufacture glasses and better melting of the raw material.