Process for making thin, sealant-coated, fiber-reinforced...

Details Process for making thin, sealant-coated, fiber-reinforced... Process for making thin, sealant-coated, fiber-reinforced...

B - Operations, Transporting

28

B

B28B 1/52 (2006.01) B32B 13/02 (2006.01) C04B 28/14 (2006.01) C04B 40/00 (2006.01)

Patent

CA 2130508

A process for making a thin, sealant-coated, tire and indentation resistant gypsum panel from at least 2 homogeneous layers of fiber-reinforced gypsum. A layer of a mixture of cellulosic fibers moistened with water and an additive to restrict the adhesion of cellulosic fiber to one another, is deposited on at least two separate conveyors to form a fibrous matt on each conveyor and a layer of dry calcined gypsum containing set accelerator is deposited on the fibrous matt on each conveyor. The deposits on each conveyor contain, on a dry weight basis, about 70% to about 90% by weight gypsum, about 10% to about 19% by weight cellulosic fiber and about 1% to about 9% by weight of combined additive and set accelerator. Each layer on each conveyor is directed to a mixing station to form a homogeneous layer, and the formed homogeneous layers on separate conveyors are placed atop one another on a single conveyor to form a combined homogeneous layer. The combined homogeneous layer is subjected to pressure (compressed) to form a pressed, homogeneous fiber-reinforced gypsum panel. A sufficient amount of water is added to the layer or layers to rehydrate the calcined gypsum. The pressed, homogeneous fiber-reinforced gypsum panel is dried, and the surface of the dried panel is sealed with a wax-free, water resistant sealant. Sealant-coated, fire resistant, indentation resistant gypsum panels having a thickness of about 0.25 inch and having a density of about 60 to 80 lbs./ft.3 are made from 2 homogeneous layers of fiber-reinforced gypsum. -35-

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