Patent ID: 7749928

Claim:
A gypsum board comprising: a gypsum core; a fiber mat comprising a first side and second side opposite the first side, the second side is bonded to the gypsum core such that a tensile strength of the bond is at least 16 pounds per square inch, wherein the gypsum core in the region of the bond has at least 17 percent combined water; and a coating penetrating the mat from the first side into the fiber mat to a depth of about 30 percent to about 50 percent of the thickness of the fiber mat, the coating comprises a mineral pigment and an organic binder, wherein the organic binder comprises at least about 1 percent and no more than 17 percent by weight and the mineral pigment has a particle size such that at least 95 percent by weight of the mineral pigment particles pass through a 100 mesh wire screen, with at least 75 percent of the particles by number being greater than 5 microns.