Composite light weight gypsum wallboard

Details Composite light weight gypsum wallboard Composite light weight gypsum wallboard

2006-09-29

2010-06-15

Sample, David R (Department: 1794)

Stock material or miscellaneous articles

Structurally defined web or sheet

Including variation in thickness

C428S703000, C106S778000, C052S553000, C156S039000

Reexamination Certificate

active

07736720

ABSTRACT:
The invention provides a light weight composite gypsum board including a foamed low density set gypsum core, a top non-foamed (or reduced-foamed) bonding high density layer and a bottom non-foamed (or reduced-foamed) bonding high density layer, a top cover sheet bonded to the foamed low density set gypsum core by the top non-foamed (or reduced-foamed) bonding high density layer, and a bottom cover sheet bonded to the foamed low density set gypsum core by the bottom non-foamed (or reduced-foamed) bonding high density layer. The foamed low density set gypsum core is prepared having a density of less than about 30 pcf using soap foam in the gypsum-containing slurry. The combination of components provide a composite gypsum board having light weight and high strength.

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