Patent ID: 8128767
Filing Date: 2012-03-06
Classification: B32B,E04C,H01F,H02K,Y10T

Abstract:
1. A process for manufacturing a paintable article comprising a hydraulic set material layer having first and second faces, and first and second facers affixed thereto, at least said first facer comprising a non-woven, fibrous mat, the process comprising: a. providing said non-woven, fibrous mat comprising a non-woven, glass fiber web having a smooth surface texture, said glass fibers consisting essentially of chopped glass fibers having an average fiber diameter ranging from about 9.5 to 12.5 μm and an average fiber length ranging from about 6 to 12 mm bound together with a resinous binder, said resinous binder comprising an acrylate copolymer latex having a glass transition temperature of about 25° C. and about 2 to 5 wt % of a crosslinker comprising melamine formaldehyde; b. forming an aqueous slurry comprising at least one member selected from the group consisting of anhydrous calcium sulfate, calcium sulfate hemi-hydrate, and hydraulic setting cement; c. distributing the slurry to form a layer on said first facer; d. applying said second facer onto the top of said layer; e. separating the resultant laminate into individual articles; and f. drying the articles, whereby said non-woven, fibrous mat of said first facer has a permeability of at least about 300 cfm/ft