Claims
- 1. A method of manufacturing a building sheet comprising the steps of:forming a mixture by adding a mineral selected from the group consisting of calcium sulfate, perlite, and combinations thereof, to a binder formulation comprising at least one self-crosslinking permanently tacky polymer, said binder formulation being selected for its ability to fully cross-link with said mineral; combining said mixture with a suitable amount of water; gradually preparing a slurry by mixing and stirring said mixture and said water to form said slurry; enveloping said slurry between two paper cover sheets to form a wet board; and drying said wet board at a temperature in the range of 75° C. to 325° C.
- 2. The method of claim 1, in which said self-crosslinking permanently tacky polymer is selected from the group of polymers consisting essentially of modified aliphatic polymer, polyurethane, vinyl acetate, sodium silicate, and polyvinyl chloride.
- 3. The method of claim 1, further comprising the step of:applying heat to said wet board during its transfer from a board forming apparatus to a drying kiln.
- 4. The method of claim 1, further comprising the step of:adding starch and borate to said binder formulation prior to mixing said binder formulation with said mineral.
- 5. The method of claim 4, in which vinyl acetate is employed as said at least one self-crosslinking permanently tacky polymer.
- 6. The method of claim 5, in which starch is present in the amount of about 0.001% to about 15% by weight.
- 7. The method of claim 6, in which starch is present in the amount of about 0.353% to about 8% by weight.
- 8. The method of claim 5, in which borate is present in the amount of about 0.001% to about 10% by weight.
- 9. The method of claim 8, in which borate is present in the amount of about 0.094% to about 2.5% by weight.
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a divisional application of U.S. patent application Ser. No. 09/374,589, filed: Aug. 13, 1999 inventor herein and entitled “STRENGTHENED, LIGHT WEIGHT WALLBOARD AND METHOD AND APPARATUS FOR MAKING THE SAME,” which application in turn is based upon and gains priority from U.S. Provisional Patent Application Serial No.: 60/139,618. filed: Jun. 17, 1999 by the inventor herein and entitled “IMPROVED WALLBOARD AND METHOD AND APPARATUS FOR MAKING THE SAME,” and is also a Continuation-in-Part Application of U.S. patent application Ser. No. 09/195,438, filed Nov. 18, 1998 by the inventor herein and entitled “LIGHT WEIGHT FIRE AND MOISTURE RESISTANT WALLBOARD.”
US Referenced Citations (1)
Number |
Name |
Date |
Kind |
6251979 |
Luongo |
Jun 2001 |
B1 |
Provisional Applications (1)
|
Number |
Date |
Country |
|
60/139618 |
Jun 1999 |
US |
Continuation in Parts (1)
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Number |
Date |
Country |
Parent |
09/195438 |
Nov 1998 |
US |
Child |
09/374589 |
|
US |