BACKGROUND

The present invention relates generally to the production of wallboard building panels, and more specifically to an improved gypsum wallboard panel that features a layer of supporting mesh for improving production of the panels, and also for providing increased nail pull resistance.

Gypsum building panels offer a high performance product for a reasonable price for finishing of building spaces. Gypsum, also known as calcium sulfate dihydrate, is heated to drive off crystalline water to produce calcium sulfate anhydrite and/or calcium sulfate hemihydrate, also known as stucco, calcined gypsum or Plaster of Paris. The building panels are made by creating a slurry, combining dry stucco with water. Calcined gypsum and water are combined and an interlocking matrix of gypsum crystals is formed. After the hydration of the calcined gypsum, excess water is driven off by heating , the resulting product is a relatively strong panel, having a good surface for receiving decorative finishes such as paint or wallpaper. One method of controlling the density of the product is by the addition of a soap-based foam to the liquid slurry. The stucco then sets around the foam bubbles, creating voids in the gypsum matrix. It is important to control the size of the bubbles to avoid undesirable properties in the panels. If the bubbles are too small, a large number of small bubbles are needed to effect the change in density. Where there are lots of bubbles in a confined space, the resulting gypsum matrix has a low compressive strength. Bubbles that are too large cause a decrease in strength and form unsightly blisters under the facing paper.

It is well known to fabricate wallboard or drywall building panels using a sheet of face paper, a slurry of gypsum, and a sheet of backing paper. These components are assembled sequentially on a moving conveyor belt. Reduction in the amount of water needed to produce gypsum is also desirable. Water in excess of that needed to hydrate the calcined gypsum is removed by kiln drying. Fuel costs to operate the drying kiln make it advantageous to reduce the amount of water in a gypsum slurry, while maintaining similar flow characteristics.

Many conventional techniques for reducing the percentage of water in the slurry have produced wallboard with reduced strength, measured as Nail Pull Resistance. In other words, the resulting panel is less resistant to being pulled back over the head of a nail driven into a supporting stud, and as such is less securely retained to the underlying building frame. US Patent No. 8,566,041 , incorporated by reference, discloses a system for calculating Nail Pull Resistance.

Further, it is known to produce wallboard panels with multi- layer gypsum construction, including a first gypsum layer located adjacent the face paper and having a first density, and a second gypsum layer applied upon the first layer. The second layer has a second density, and the density of the second layer is lower than that of the first layer. The higher density of the first layer, achieved by the injection of less foam or water as discussed above, has been found to bond more securely to the face paper.

An alternative technique is to differentiate the first and second layers by the addition of different amounts of starch to the slurry, with the first layer receiving more starch than the second layer, to increase strength. During the production of such wallboard panels, it is not uncommon for the flowing of the second layer upon the first layer on the moving production line to cause at least a partial "washout" of the first layer, due to the relatively high velocity of the output of the second layer from the mixer, compared to the conveyor belt line speed. In one example, the output velocity of the slurry forming the second layer is one and a half to three times the speed of the conveyor line. This "washout" disrupts, misaligns or otherwise interferes with the proper positioning and formation of the first layer, which ultimately results in substandard panels.

Accordingly, there is a need for an improved wallboard production system resulting in reduced "washout" and ultimate wallboard panels having increased Nail Pull Resistance.

SUMMARY

The above-listed needs are met or exceeded by the present wallboard panel which features a face paper covering, a first layer of relatively high density gypsum formulation; a web of supporting mesh in the first layer, preferably near the face paper, a second layer of relatively lower density gypsum formulation, and a sheet of backing paper. It has been found that the mesh supports and protects the first layer of gypsum slurry, having the higher density, from the effects of the impact of relatively high velocity slurry used to form the second, relatively lower density layer of gypsum. In a preferred embodiment, the mesh is in contact with the face paper, and also provides enhanced Nail Pull Resistance.

In the present application, "mesh" refers to any perforated, breathable substrate that is provided in web or mat format and is constructed and arranged to be installed as a web or sheet upon a gypsum production line from a roll of such material. Suitable mesh includes but is not limited to nonwoven or woven fiber mats of polymers or other materials, perforated film, screening material, or the like.

Preferably, the mesh has a thickness in the range of .015 inch, similar to the thickness of a sheet of heavy paper.

In a preferred embodiment, the first layer has a relatively higher concentration of starch than the second layer. Also, the mesh is either laid upon the first layer during board production, or is pressed or embedded into the first layer prior to application of the second layer. It is preferred that the mesh be disposed in the first layer in relatively close proximity to, or in contact with, the face paper for achieving desired increased Nail Pull Resistance. In another preferred

embodiment, the second layer of gypsum formulation also penetrates the mesh.

More specifically, the present invention provides a wallboard panel, including a sheet of face paper, a first layer of gypsum composition having a first density, a web of mesh associated with the first layer of gypsum composition, a second layer of gypsum

composition having a second density, the second density being lower than the first density, and

a layer of backing paper.

In an embodiment of the present panel, the web of mesh is disposed in the first layer of gypsum to be closer to the sheet of face paper than to the backing paper. In an embodiment of the present panel, the first layer of gypsum composition has a first thickness and the second layer of gypsum composition has a second thickness, wherein the second thickness is greater than the first thickness. In an

embodiment of the present panel, the first layer of gypsum composition has a greater weight percentage of starch than the second layer of gypsum composition. In an embodiment of the present panel, the first layer of gypsum composition has a density in the range of 26-40 pcf, and the second layer of gypsum composition has a density in the range of 22-30 pcf. In an embodiment of the present panel, the mesh is taken from the group consisting of nonwoven or woven fiber mats of polymers or other materials, perforated film, screening material. In an

embodiment of the present panel, the mesh is embedded into the first layer of gypsum composition and has an approximate thickness of 0.015 inch. In an embodiment of the present panel, the mesh contacts the face paper and the second layer of gypsum composition is embedded into the mesh. In another embodiment, a method of producing wallboard panels, is provided, including providing a sheet of face paper and laying same upon a moving conveyor belt, applying a first layer of gypsum composition slurry upon the sheet of face paper, applying a web of mesh upon the first layer of gypsum composition slurry, applying a second layer of gypsum composition slurry upon the web of mesh, and applying a sheet of backing paper upon the second layer of gypsum composition slurry.

In an embodiment, the method further includes providing the first gypsum composition with at least one of a first thickness and a first density; and the second gypsum composition with at least one of a second thickness and a second density, wherein the first thickness is smaller than the second thickness and the first density is greater than the second density, adding starch to at least one of the first and second layers of gypsum composition, wherein the first layer of gypsum composition has a greater weight percentage of starch than said second layer of gypsum composition, providing the first gypsum composition with starch in the approximate range of 20% weight percent, and providing the second gypsum composition with starch in the

approximate range of 4% weight percent.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic fragmentary vertical cross-section of a prior art composite wallboard panel;

FIG. 2 is a schematic fragmentary vertical cross-section of the present wallboard panel, including enlarged micrographs of suitable mesh materials;

FIGs. 2a-c are enlarged photomicrographs of suitable mesh materials;

FIG. 3 is a schematic fragmentary enlarged vertical cross- section of a lower portion of the panel of FIG. 2; FIG. 4 is a fragmentary schematic side elevation of a wallboard production line suitable for making the present wallboard panels;

FIG. 5 is an enlarged fragmentary elevation of FIG. 4; FIG. 6 is a fragmentary schematic side elevation of an alternate embodiment of the wallboard production line of FIG. 4; and

FIG. 7 is a fragmentary enlargement of FIG. 6.

DETAILED DESCRIPTION

Referring now to FIG. 1 , a prior art so-called "composite" gypsum wallboard panel is generally designated 10, and includes a sheet of face paper 12, a top core of relatively dense gypsum

formulation 14, a bottom core of relatively less dense gypsum

formulation 16, and a sheet of backing paper, also referred to as craft paper 18. As is known in the art, and as described in greater detail below, the panel 10 is produced with the face paper sheet 12 contacting a moving belt of the conveyor line, and as such the panel is

constructed "face paper down" or inverted from the orientation shown in FIG. 1. The face paper sheet 12 has a preferred thickness in the range of 0.012 to 0.015 inch, and most preferably 0.013 inch.

As is known with such composite panels 10, both the top core layer 14 and the bottom core layer 16 are compositions of calcium sulfate hemihydrate, water, a foaming agent and stabilizers as are well known in the art. Suitable gypsum wallboard compositions are described in commonly owned US Patent Nos. 1 ,500,452; 2,207,339; 4,009,062; 5,922,447; 8,470,461 ; and 8,142,914, all of which are incorporated by reference.

Referring now to Table 1. below, in the panel 10, the top core layer 14 is made from a relatively high density calcium sulfate hemihydrate slurry with a density in the general range of 26-40 pcf and a thickness in the general range of 0.015-0.035 inch prior to setting or "wet", which becomes thinner upon setting or drying, to be in the range of 0.005-0.010 inch. In one embodiment, the top core layer 14 has a thickness of 0.008 inch. The bottom core layer 16 is made from a relatively low density calcium sulfate hemihydrate slurry with a density in the general range of 22-30- pcf and a thickness in the general range of 0.432 to 0.422 inch. In other words, the bottom core layer 16 has a density ranging from 60% to 92% of the density of the relatively denser top core layer 14. Also, the thickness of the top core layer 14 relative to the bottom core layer 16 ranges generally from 9% to 12%.

The greater density in the top core layer 14 is usually achieved through application of water and/or foam, as is well known in the art. However, another technique is to add greater percentages of starch, strength additives, water resistance additives, fire resistance materials, among others to the top core layer 14 to increase its strength and other preferred properties. Preferably, the starch is found in the approximate range of 10 to 20% weight percent of the stucco weight used to make the top core layer 14, compared to approximately 2 to 4% weight percent starch of stucco weight in the bottom core layer 16.

During production of the panel 10, after the face paper sheet 12 is laid upon the production line conveyor belt, the relatively denser gypsum slurry forming the top core layer 14 is poured upon the face paper. Next, the relatively less dense gypsum slurry forming the bottom core layer 16 is poured upon the top core layer 14. As

described above, it has been found that, during production, the application of the bottom core layer 16 causes unwanted "washout" of the top core layer 14 because the former is applied at a much greater velocity (at least as much as three times greater) than the speed of the board conveyor.

Referring now to FIGs. 2 and 3, the present wallboard panel is generally designated 20. Components shared with the panel 10 are designated with identical reference numbers. Also, the layers 14, 16 are basically the same in composition and relative density in both the panel 10 and the panel 20. In FIG. 2, the panel 10 is shown inverted, with the face paper sheet 12 at the bottom, which is the orientation of the panel as it emerges from the production line. A main distinctive feature of the panel 20 is the inclusion of a web of mesh 22 in close proximity to the first layer, or the top core 14. As seen in FIGs. 2 and 3, the mesh web 22 preferably contacts the face paper 12.

Referring now to FIGs. 2 a-c, as described above, the web of mesh 22 refers to any perforated, breathable substrate that is provided in web or mat format and is constructed and arranged to be installed as a web or sheet upon a gypsum production line from a roll of such material. Suitable mesh includes but is not limited to fine mesh nonwoven fiber mats, such that the randomly distributed openings between the randomly distributed fibers are significantly smaller than the shank diameter of a typical wallboard nail (at least 0.098 inch) ;(FIG. 2a); relatively coarser mesh nonwoven fiber mats with randomly distributed openings in the range of 0.078 to 0.236 inch diameter (FIG. 2b); screen cloth or structured fibers with openings of approximately 0.078 inch. (FIG. 2c); as well as woven fiber mats of polymers or other materials, perforated film, screening material, or the like. A preferred thickness of the mesh web is in the range of 0.010-0.030 inch, and a further preferred thickness is in the range of 0.015-0.020 inch, or approximately the same thickness as a sheet of paper.

It has been found that by associating the mesh web 22 with the top core material 14, the unwanted washout is prevented during board production as the lower density core or bottom layer 16 is applied. Instead, the distribution of the initially applied top core layer 14 is more evenly distributed in the resulting panel as a result of the action of the mesh web 22. An added benefit of the present mesh web 22 is that the Nail Pull Resistance of the resulting panel is significantly improved. In board production, increasing density of the top core 14 alone has not been found to improve Nail Pull Resistance. Instead, such higher density layers are in some cases more prone to cracking. Still another advantage of the present mesh web 22 is that it has been found to enhance crystal development as the gypsum sets in the mesh.

Referring now to FIGs. 4 and 5, a wallboard panel production apparatus is schematically illustrated and generally designated 28 for disclosing a preferred method for producing the wallboard panels 20. First, as is typical in wallboard manufacturing, a conveyor table 30 supports a moving conveyor belt (not shown) upon which is laid the face paper 12, with the outer surface facing the belt, as is well known in the art. The face paper 12 is supplied from a roll 32, and is maintained at a proper tension through the use of at least one idler roller 34.

Next, the relatively denser, and relatively thinner top core composition 14 is applied in slurry form through a designated mixer outlet 36 upon the face paper 12. A rotating forming roller 38 is disposed at a desired height relative to the conveyor table 30 for forming and leveling the top core 14. The web of mesh 22 is applied upon the top core 14 and is supplied from a roll 40. A rotating press roller 42 maintains tension on the mesh web 22, and also presses the mesh web into the top core 14, which has not yet set. It is preferred that the mesh web 22 be embedded into the top core 14 so that the mesh is closer to the face paper 12 than to the backing paper 18, a variety of mesh positions within the top core are contemplated. It is further preferred that the mesh 22 is in contact with the face paper 12.

After the mesh web 22 is embedded into the top core 14, the relatively lower density, and relatively thicker bottom core 16 is applied upon the mesh web 22 in slurry format through a mixer outlet 44. As is known in the art, the mixer outlet emits the slurry of the bottom core 16 at a velocity that is in some cases as much as three times the speed of the board line, having a speed in the range of 100- 680 ft./min. This relatively higher velocity has been known to cause the unwanted "washout" of the top core 14 as described above. However, the application of the mesh web 22 has been found to prevent washout, and maintain the desired form of the top core 14. Another contemplated embodiment is to have the bottom layer slurry 16 penetrating the mesh web 22 on the moving conveyor belt with the aid of table vibration provided by a conventional conveyor vibrator, represented by 43. After application of the bottom core slurry 16, the backing paper 18 is applied from a supply roll (not shown) as is well known in the art.

Subsequently, the panel is allowed to set, is trimmed and passed to a drying kiln as is well known in the art.

Referring now to FIGs. 6 and 7, an alternate apparatus generally designated 46 is provided for forming the present panel 20. Components shared with the apparatus 28 of FIGs. 4 and 5 are designated with identical reference numbers. The main distinguishing feature of the apparatus 46 is that a rotating embedding roller 48 forms the top core slurry 14, maintains tension on the mesh web 22 and also embeds it into the top core. All of the other features of the apparatus 46 correspond to the apparatus 28.

Referring now to Table 2 below, besides the advantage of 5 preventing unwanted washout, it has been found that by adding the mesh web 22 to the top core layer 14, the Average Nail Pull Resistance is increased. The Average Nail Pull Resistance in (Ibf) ranges from

713 to 104.9 Ibf The highest Nail Pull Resistance values were obtained using the relatively fine mesh non-woven web as seen in 10 FIG. 2(a). Also, it will be seen for each lab sample ID, having the same density, adding the mesh web 22 enhanced the Nail Pull values significantly. Also, the greatest improvement in Nail Pull Resistance, approximately 20% improvement, was achieved using the fine mesh non-woven web of FIG. 2(a). in Table 2, in the Dispersant column, 15 PCE refers to Polycarfooxy!ate Ether, and PNS refers to Napthalene Sulfonate.

Table 2. Nail Pull Data with and without porous mesh web Thus, it has been shown that by providing the mesh web 22 in the top core layer 14, not only has unwanted washout been prevented, but Nail Pull Resistance is improved.

While a particular embodiment of the gypsum wallboard with reinforcing mesh has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.