Patent ID: 8039058

Claim:
A method for forming a gypsum facer comprising: forming a randomly oriented open mesh filament network; optionally applying at least one reinforcing agent to said open mesh filament network prior to adding any binder; impregnating said randomly oriented open mesh filament network with a first binder resin to form a wet formed permeable precursor mat; applying at least one reinforcing agent to said open mesh filament network; coating said wet formed permeable precursor mat with a secondary coating, said secondary coating comprising a low glass transition organic binder and at least one filler, and said secondary coating having a viscosity sufficient to prevent full penetration of said secondary coating within said randomly oriented open mesh filament network; drying said coated wet formed permeable precursor mat within a drier at a temperature sufficient for said first binder resin to form a film; forming a secondary veil, said secondary veil comprising a plurality of polymeric fibers having a length sufficient to bridge each of a plurality of pores defined within said randomly oriented open mesh filament network; and layering said secondary veil onto said randomly oriented open mesh filament network prior to impregnating said precursor matting with said first binder resin.