Patent ID: 7763134

Claim:
A process of manufacturing a construction board which comprises (1) positioning a wet gypsum composition between a first facer and a second facer to make a laminated sheet of wet construction board, wherein the first facer is comprised of a breathable film and a glass-mat, wherein the breathable film and the glass mat are bonded together with an adhesive, wherein the breathable film is comprised of a breathable polymeric material selected from the group consisting of nylons and thermoplastic elastomers, wherein the breathable film has a thickness which is within the range of 0.9 mils to 1.2 mils, wherein the breathable film is a microporous membrane, and wherein the polymeric material is water resistant, and (2) heating the laminated sheet of wet construction board to an elevated temperature for a period of time which is sufficient to reduce the moisture content of the gypsum to be within the range of 18 to 25 percent.