Lightweight, high-strength gypsum board

Abstract

A system and method for manufacturing a lightweight, high-strength gypsum board is provided. The lightweight, high-strength gypsum board includes a gypsum layer formed from a gypsum slurry, the gypsum layer having a bottom and a top. The gypsum slurry includes a polymer foam and, optionally, a soap solution. The gypsum board further includes a first mat disposed on the bottom of the gypsum layer and a second mat disposed on the top of the gypsum layer. The gypsum slurry may optionally include reinforcing fibers.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Provisional Patent Application No. 63 / 419,349, filed October 26, 2022, and entitled "LIGHTWEIGHT HIGH-STRENGTH GYPSUM BOARD," which is incorporated herein by reference in its entirety.

[0002] The present invention relates generally to the field of gypsum board products, and more particularly to lightweight, high-strength gypsum boards having a polymer foam core and reinforcing fibers. [Background technology]

[0003] Architectural panels, such as interior wallboard, architectural sheathing, or roofing panels, include a core material, such as gypsum. The architectural panels also include a mat facer, such as a fiberglass mat or a paper facer. During manufacturing, the gypsum core material may be applied as a slurry to the surface of the glass mat or paper facer and allowed to set so that the mat facer and gypsum core are bonded at their interfaces. Applicants have identified several performance problems that can arise from manufacturing architectural panels. Summary of the Invention [Problem to be solved by the invention]

[0004] Through the application of hard work, ingenuity, and innovation, applicants have solved problems related to lightweight, high-strength gypsum board by developing the solutions embodied in this disclosure, described in detail below. [Means for solving the problem]

[0005] According to one embodiment of the present disclosure, there is provided a high-strength, lightweight gypsum board having a polymer foam core. The gypsum board includes a gypsum layer formed from a gypsum slurry, the gypsum layer having a bottom and a top. The gypsum slurry includes a polymer foam. The gypsum board further includes a first mat disposed on the bottom of the gypsum layer and a second mat disposed on the top of the gypsum layer. The gypsum slurry optionally includes a soap solution, the polymer foam and the soap solution being in a predetermined mixing ratio.

[0006] According to one embodiment of the present disclosure, a slate coat layer may be present between the gypsum core and the top or bottom layer. The gypsum board includes a gypsum layer formed from a gypsum slurry, the gypsum layer having a bottom and a top. The gypsum slurry includes a polymer foam. The gypsum board further includes a first mat disposed on the bottom of the gypsum layer and a second mat disposed on the top of the gypsum layer. The slate coat layer is a high-density gypsum layer present between the mat (first or second) and the gypsum core. The slate coat may be present on at least one side of the board. The gypsum slurry or core optionally includes a soap solution, the polymer foam and the soap solution being in a predetermined mixing ratio.

[0007] According to yet another embodiment of the present disclosure, there is provided a method for manufacturing a high-strength, lightweight gypsum board. The method includes forming a gypsum layer from a gypsum slurry, the gypsum layer having a bottom and a top. The gypsum slurry includes a polymer foam. The method further includes positioning a first mat on the bottom of the gypsum layer and a second mat on the top of the gypsum layer. The gypsum slurry optionally includes a soap solution, the polymer foam and the soap solution being in a predetermined mixing ratio.

[0008] Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the present invention, together with its advantages and features, reference is made to the description and drawings.

[0009] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a cross-sectional view of an exemplary gypsum panel according to various embodiments. [Figure 2] FIG. 1 is a cross-sectional view of an exemplary gypsum panel according to various embodiments. [Figure 3] 1 depicts a schematic diagram of an exemplary gypsum core with polymer foam, according to various embodiments. [Figure 4A] 1 depicts a cross-sectional view of an exemplary gypsum panel, according to various embodiments. [Figure 4B] 1 depicts a cross-sectional view of an exemplary gypsum panel, according to various embodiments. [Figure 4C] 1 depicts a cross-sectional view of an exemplary gypsum panel, according to various embodiments. [Figure 4D] 1 depicts a cross-sectional view of an exemplary gypsum panel, according to various embodiments. [Figure 5A] 1 depicts an exemplary foam, according to various embodiments. [Figure 5B] 1 is a chart depicting foam stability for various foam to soap ratios according to various embodiments. [Figure 6A] 1 is a chart depicting a comparison of compression test results according to various embodiments. [Figure 6B] 1 is a chart depicting a comparison of push-through test results according to various embodiments. [Figure 7A] 1 is a chart depicting a comparison of pull-out test results according to various embodiments. [Figure 7B] 1 is a chart depicting a comparison of bend test results according to various embodiments. [Figure 8A] 1 depicts reduced dust when cutting boards made according to embodiments herein. [Figure 8B]1 depicts reduced dust when cutting boards made according to embodiments herein. [Figure 9] 10 is a chart depicting a comparison of nail pull results for boards having reinforcing fibers according to various embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0011] The present invention is now described in detail, by way of example only, with reference to the following drawings. Modifications of the various embodiments illustrated within the spirit and scope of the invention will be readily apparent to those skilled in the art.

[0012] Embodiments herein provide a gypsum core having a polymer foam incorporated therein, resulting in a lighter weight core and a stronger gypsum core, due at least in part to the air bubbles formed from the incorporation of the polymer foam. Figure 3 depicts a schematic diagram of an exemplary gypsum core with a polymer foam, according to various embodiments. In Figure 3, the polymer foam is incorporated into the gypsum core to provide additional structural integrity to the gypsum core. That is, the polymer foam introduces air bubbles within the foam, which provide increased resistance to applied forces to the gypsum core as a result of being reinforced by the polyfoam (as opposed to simply air bubbles). The polymer foam further provides better adhesion and structural integrity to the gypsum core. In embodiments, the polymer can be a styrene butadiene copolymer, which can be mixed in different ratios with a blowing agent. In some embodiments, the polymer foam can be polyvinyl alcohol, acrylonitrile butadiene styrene, other expandable polymers, or air bubbles such as polymer microspheres or hollow glass spheres. According to various embodiments, the styrene butadiene copolymer exhibits a range of styrene:butadiene molar ratios.

[0013] Embodiments herein further provide gypsum panels or boards having the improved gypsum core described above, as well as reinforcing fibers incorporated into the gypsum core or into one or more fibrous mats of the gypsum panel or board. In some embodiments, the reinforcing fibers are introduced over or replace existing glass fibers. Examples of reinforcing fibers include polyamide fibers, polyimide fibers, cellulose fibers, polypropylene or polyethylene fibers, hemp fibers, polyvinyl alcohol fibers, carbon fibers, glass fibers, different types of glass fibers such as A, E, C, AE, or S, basalt fibers, etc.

[0014] Embodiments herein that include polymer foam and reinforcing fibers in a gypsum core result in a weight reduction of approximately 20% by weight and gypsum boards with similar or better strength properties. In certain embodiments, the weight reduction can be in the range of approximately 10% to 30%. In other embodiments, the range can be 15% to 25%. For example, a board range of 2000 to 2500 lb / msf can be lightened approximately 20% to 1600 to 1920 lb / msf. Or, in another scenario, a board with 1450 to 1650 lbs / msf can be lightened approximately 20% to 1160 to 1320 lbs / msf.

[0015] The weight reduction rate to produce lighter boards also allows manufacturers to use less raw material, thereby allowing for faster line speeds and / or drying, which may save energy. A lighter product also allows for easier on-site installation and facilitates easier transportation of the boards to the site, which further improves the sustainability of manufacturing.

[0016] In some embodiments, a gypsum panel or board may contain a set gypsum core disposed (or "sandwiched") between two mats, one or both of which may be coated with a mat coating. In some embodiments, a mat coating, as used herein, is a substantially continuous barrier coating, which refers to a coating material that is substantially uninterrupted (i.e., substantially continuous) across the surface of the mat. In some embodiments, the mat coating is a porous material configured to allow leakage (e.g., via evaporation) from the gypsum panel or board.

[0017] In some embodiments, during manufacturing, a gypsum slurry is deposited onto the uncoated surface of a facing material, such as a paper sheet or fiberglass mat (which may be pre-coated before manufacturing), and solidified to form the gypsum core of the gypsum panel. In some embodiments, the gypsum slurry penetrates a portion of the thickness of the fiberglass mat or paper sheet, at least in this way providing a mechanical bond for the panel. Gypsum slurries containing binders such as starch can form chemical hydrogen bonds with the paper facing material. The gypsum slurry can be provided in one or more layers having the same or different compositions, including one or more slate coat layers. As used herein, the term "slate coat" refers to a gypsum slurry having a higher wet density than the remainder of the gypsum slurry that forms the gypsum core.

[0018] In certain embodiments, as shown in FIG. 1 , gypsum panel 100 includes a gypsum core 101 having a first surface and a second opposing surface, and a first facing material 104 (shown here as a fibrous mat, but it is understood that the facing materials described herein may be paper facings or other suitable materials) associated with the first surface of gypsum core 101 such that the gypsum of the gypsum core penetrates at least a portion of first mat 104. The various layers are illustrated as separate layers in the figures for ease of illustration. However, it should be understood that overlap of these materials may occur at their interfaces. In certain embodiments, gypsum panel 100 includes set gypsum core 101 associated with the first surface of first fibrous mat 104, and an optional mat coating 106 applied to the second surface of first fibrous mat 104.

[0019] In some embodiments, as shown in FIG. 1 , the slurry of gypsum core 101 (e.g., gypsum containing a hydrophobic additive such as siloxane) infiltrates the remainder of first fibrous mat 104 such that voids within mat 104 are substantially eliminated, further improving the water resistance of panel 100. For example, in one embodiment, first mat 104 has a mat coating 106 on a surface opposite gypsum core 101, which mat coating 106 infiltrates a portion of first mat 104 to define the remainder of first mat 104. That is, the gypsum of gypsum core 101 can infiltrate the remaining fibrous portion of first fibrous mat 104 such that voids within first fibrous mat 104 are substantially eliminated. In one particular embodiment, mat 104 is a nonwoven glass fiber mat. In various embodiments, the gypsum board can have glass mats as the top and bottom surfaces or can be paper sheets as the top and bottom surfaces.

[0020] In certain embodiments, as shown in Figure 1, a gypsum core 101 includes two or more gypsum layers 102, 108. For example, the gypsum core may include various gypsum layers having different compositions. Similar to layer 102, layer 108 may be denser, like a slate coat, compared to layer 108.

[0021] In one particular embodiment, as shown in Figure 2, gypsum panel 200 includes two fibrous mats 204, 212 associated with gypsum core 201. Second mat 212 is on the side of gypsum core 201 opposite first mat 204. In some embodiments, only first mat 204 has mat coating 206 on its surface. In other embodiments, both mats 204, 212 have coatings 206, 214 on their surfaces opposite gypsum core 201. In some embodiments, gypsum core 201 includes three gypsum layers 202, 208, 210.

[0022] 4A-4D depict cross-sectional views of an exemplary gypsum panel 300. In some embodiments, exemplary gypsum panel 300 may include gypsum core 301. In some embodiments, exemplary gypsum panel 300 may include one or more layers 302A, 302B. In some embodiments, gypsum panel 300 may include one or more coats 304A, 304B. In some embodiments, gypsum panel 300 may include multiple additives 306. In some embodiments, as shown at least in FIG. 4B, polymer layer 308 may be disposed as a layer around additive 306 or around hollow core 314. In some embodiments, as shown at least in FIGS. 4C and 4D, gypsum panel 300 may include one or more reinforcing fibers 310. In some embodiments, gypsum core 301 may include polymer material 312.

[0023] In various embodiments, the gypsum core comprises a polymer foam and, optionally, a soap solution. References to soap solution herein refer to foaming agent surfactants used in the gypsum industry to generate foam in gypsum panels. For example, anionic or amphoteric surfactants may be used in some embodiments. Exemplary anionic surfactants include (but are not limited to) Hyonic® foaming agent from GEO, Cedepal® foaming agent from Stepan Company, Alpha Foamer® G available from Stepan Company, and Enafoam WB 5 available from Enaspol Company. In various embodiments, the gypsum core is made from a gypsum slurry comprising a polymer foam (e.g., 3-50% in water) and a soap solution (e.g., 0.1-5% in water) in a 1:1 ratio. In some embodiments, the gypsum slurry can comprise a polymer foam and soap solution in a weight ratio of ≧0.1:1 to ≦10:1 (e.g., ≧0.2:1 to ≦5:1 or ≧0.5:1 to ≦2:1). The polymer foam and soap solution can be premixed and foamed before being mixed into the gypsum slurry to provide a foamed gypsum slurry. The polymer foam and soap can also be added simultaneously to the gypsum slurry and foamed in situ (e.g., in a slurry mixer) to provide a foamed gypsum slurry. Some of these embodiments can incorporate reinforcing fibers (e.g., 310 as shown at least in FIGS. 4C and 4D) including polyamide fibers or glass fibers or combinations (e.g., 1-15 lbs / msf).

[0024] In various embodiments, the gypsum core is made from a gypsum slurry containing polymer foam and soap solution in a ratio of 3: 1. Some of these embodiments can incorporate reinforcing fibers including polyamide fibers or glass fibers or combinations (e.g., 1-32 lbs / msf, 1-24 lbs / msf, 1-15 lbs / msf, or 1-12 lbs / msf).

[0025] In various embodiments, the gypsum core is made from a gypsum slurry containing polymer foam and soap solution in a 1:1 ratio. Some of these embodiments can incorporate reinforcing fibers, including polypropylene fibers or glass fibers, or combinations (e.g., 1-15 lbs / msf).

[0026] In various embodiments, the gypsum core is made from a gypsum slurry containing polymer foam and soap solution in a ratio of 3: 1. Some of these embodiments can incorporate reinforcing fibers including polypropylene fibers or glass fibers or combinations (e.g., 1-15 lbs / msf).

[0027] Although ratios of 1:1 and 3:1 are specified hereinabove, it should be understood that a range of ratios near these values ​​may also be utilized without departing from the scope and spirit of the present invention.

[0028] Other possible combinations for foaming may not be limited to two components, such as soap and polymer foam, but may also include combinations of two or more polymer foam systems (such as styrene-butadiene copolymer with polyvinyl alcohol) in different ratios with or without a soap solution. For example, another possible combination may be polymer foam alone further combined with reinforcing fibers, with or without the addition of a soap solution. Based on the addition rate to generate the polymer foam, different ratios of varying amounts of polymer can be incorporated into the core, which may range from 0.05 to 15 lbs / msf added to the core.

[0029] In various embodiments, a polymer matrix or network can be incorporated into the gypsum core or gypsum layer, either directly on the gypsum core or on top of the reinforcing fibers on the gypsum core. The polymer matrix provides further improved adhesion of the gypsum molecules and increased strength properties.

[0030] In various embodiments, the polymer matrix can be incorporated into a gypsum core or layer that is added over the polymer foam and reinforcing fibers.

[0031] The polymer added onto the polymer foam can be of the same type or different and can be added in any ratio compared to the foam.

[0032] In some of these embodiments, the gypsum core is made according to embodiments herein and incorporates a polymer matrix (e.g., Lipton 8100, e.g., up to 10 lbs / msf, up to 32 lbs / msf) as well as polyamide fibers (e.g., 1-15 lbs / msf).

[0033] In some of these embodiments, the gypsum core is made according to embodiments herein and incorporates a polymer matrix (e.g., Lipton 8100, e.g., up to 10 lbs / msf, up to 32 lbs / msf) as well as polypropylene fibers (e.g., 1-15 lbs / msf).

[0034] In some of these embodiments, the gypsum core is made according to embodiments herein and incorporates a polymer matrix (e.g., Lipton 8100, e.g., up to 10 lbs / msf, up to 32 lbs / msf) as well as cellulose fibers (e.g., 1-15 lbs / msf).

[0035] In some of these embodiments, gypsum boards were prepared with a slate coat layer incorporated between the glass mat and the core. Polymer foam using Lipaton 8100 (10% diluted solution) was mixed with a soap solution in a 1:1 ratio. Glass fiber was also added for reinforcement up to 9 lbs / msf. The resulting boards were 20% lighter than the control. The outer layer was coated glass mat.

[0036] In some of these embodiments, the gypsum board may include a slate coat layer incorporated between the glass mat and the core with an outer layer of coated glass mat. In some embodiments, a polymer foam using Lipton 8100 (10% diluted solution) may be mixed with a soap solution in a 1:1 ratio. In some embodiments, polypropylene fibers, such as up to 9 lbs / msf, may be added, at least for reinforcement purposes. In some embodiments, boards constructed according to these described specifications were 20% lighter than control boards. In one particular combination, a polymer foam was prepared via polyvinyl alcohol (5% diluted solution) and mixed with a soap solution in a 1:1 ratio.

[0037] A table is provided below representing the data collected for the different formulations, demonstrating the benefits of the lighter weight boards with polymer foam and fiber compared to the lighter weight control boards.

[0038] [Table 1]

[0039] Compression tests were also conducted to compare the strength of the core cubes. Samples (cubes prepared as 2-inch cubes in a mold without facer mats) were dry tested for compression, and the cubes made with polymer foam and reinforcing fibers gave better strength properties compared to the cubes made with only soap solution as a lightweight control (as shown in the table above).

[0040] Figure 5A depicts an exemplary foam according to various embodiments. Figure 5B is a chart depicting foam stability for various foam-to-soap ratios according to various embodiments. In Figure 5A, Lipton 8100 is foamed according to different ratios with soap solution, and Figure 5B shows the resulting stability.

[0041] Figure 6A is a chart depicting a comparison of compression test results according to various embodiments. In Figure 6A, a gypsum board without polymer foam and without reinforcing fiber in the gypsum core (e.g., the control in Figure 6A) was compared to a gypsum board with double the foam level (e.g., the control with double foam in Figure 6A), as well as a gypsum board with polymer foam (with a 1:1 soap-to-polymer ratio) and reinforcing fiber (e.g., the 1:1 foam + fiber in Figure 6A), and a gypsum board with polymer foam (with a 1:3 soap-to-polymer ratio) and reinforcing fiber (e.g., the 1:3 foam + fiber in Figure 6A). The gypsum board with polymer foam and reinforcing fiber exhibited weight reduction and strength properties comparable to the control in Figure 6A.

[0042] Figure 6B is a chart depicting a comparison of push-through test results according to various embodiments. In Figure 6B, a gypsum board without polymer foam and without reinforcing fiber in the gypsum core (e.g., the control in Figure 6B) was compared to a gypsum board with polymer foam (having a 1:1 soap-to-polymer ratio) and reinforcing fiber (e.g., the 1:1 foam + fiber in Figure 6B), and a gypsum board with polymer foam (having a 1:3 soap-to-polymer ratio) and reinforcing fiber (e.g., the 1:3 foam + fiber in Figure 6B). The gypsum board with polymer foam and reinforcing fiber exhibited reduced weight and strength properties comparable to the control in Figure 6B.

[0043] 7A is a chart depicting a comparison of pull-out test results according to various embodiments. FIG. 7B is a chart depicting a comparison of flexural test results according to various embodiments. For the results of FIGS. 7A and 6B, gypsum boards of different dimensions (e.g., Sample 1 is 14×14 inches and Sample 2 is 12×16 inches) were prepared with both polymer foam and reinforcing polypropylene fiber in the gypsum core. Both samples provided a reduction in weight and an increase in strength compared to gypsum boards without polymer foam and reinforcing fiber (e.g., the control in FIGS. 7A and 7B).

[0044] 8A and 8B depict reduced dust when cutting boards made according to embodiments herein. Figure 8A depicts cutting a gypsum board made without additional polymer in the gypsum core according to embodiments herein, and Figure 8B depicts cutting a gypsum board made with additional polymer in the gypsum core. As can be seen in Figures 8A and 8B, the polymer in the gypsum core acts as a binder for the gypsum powder, resulting in less dust spreading from cutting the gypsum board.

[0045] 9 is a chart depicting a comparison of nail pull test results for boards with reinforcing fibers according to various embodiments. Nail pull tests are performed according to standard test methods for physical testing of gypsum panel products (e.g., ASTM-C473). Nail pull tests are performed by drilling a small pilot hole in the panel (e.g., gypsum board) under test. A nail shank attachment is then driven into the pilot hole, thereby creating a crack in the gypsum board or panel, and the load is recorded until failure.

[0046] Introducing fibers into the core of gypsum boards or panels according to embodiments herein may require better or improved distribution and better or improved interaction with gypsum molecules. Depending on the fibers introduced, the fibers may be well distributed within the core, such as hydrophilic fibers. Glass fibers, PVA, and PP can be plasma treated (or corona treated via a bulk drum treater or treated with a surfactant) to improve gypsum adhesion to the fibers in the core, thereby reducing crack propagation. Increased gypsum adhesion to the fibers can increase the ability to prevent shear load-related failure in the core during nail pull tests. As shown in Figure 9, plasma-treated fibers resulted in improved nail pull values.

[0047] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0048] Corresponding structures, materials, acts, and equivalents of all means or steps and functional elements within the scope of the following claims are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the invention. The embodiments have been chosen and described to best explain the principles of the invention and practical application and to enable others skilled in the art to understand the invention in various embodiments with various modifications suited to the particular uses contemplated.

[0049] While preferred embodiments of the present invention have been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements that fall within the scope of the following claims, which claims should be construed to maintain appropriate protection for the invention as first described.

Claims

1. A gypsum board, A gypsum layer comprising a gypsum slurry configured to improve one or more of the strength, nail pull resistance, pull-out resistance, push-through resistance, flexural strength, compressive strength, or shear strength of the gypsum board; a gypsum layer including a bottom, a top, and a polymer foam; a first mat disposed on the bottom of the gypsum layer; a second mat disposed on top of the gypsum layer; gypsum board, wherein one or more of the gypsum slurry, the first mat, or the second mat comprises reinforcing fibers.

2. The gypsum board of claim 1 , wherein the gypsum layer further comprises a soap solution.

3. 3. The gypsum board of claim 2, wherein the gypsum slurry comprises a polymer foam and a soap solution in a predetermined mix ratio, the predetermined mix ratio comprising ≧1:1 or 1:≧1.

4. The gypsum board according to claim 3, wherein the predetermined mixing ratio includes ≧0.1:1 to ≦10:1, ≧0.2:1 to ≦5:1, or ≧0.5:1 to ≦2:

1.

5. 5. The gypsum board of claim 4, wherein the predetermined mix ratio comprises a 1:1 ratio of 3-50% polymer foam in water to 0.1-5% soap solution in water.

6. 6. The gypsum board of claim 5, wherein the gypsum slurry comprises 0.05 to 15 lbs / msf of polymer foam.

7. 7. The gypsum board of claim 6, wherein the predetermined mix ratio comprises a 3:1 ratio of 3-50% polymer foam in water to 0.1-5% soap solution in water.

8. 8. The gypsum board of claim 7, wherein the gypsum slurry comprises 0.05 to 15 lbs / msf of polymer foam.

9. 2. The gypsum board of claim 1, wherein the reinforcing fibers comprise one or more of polyamide fibers, polyimide fibers, cellulose fibers, polypropylene fibers, polyethylene fibers, polyvinyl alcohol fibers, hemp fibers, carbon fibers, or glass fibers or different types of glass fibers (A, C, E, AE, or S).

10. The gypsum board of claim 1 , wherein the reinforcing fibers include polypropylene fibers in combination with polyamide fibers.

11. The gypsum board according to claim 1 , wherein the reinforcing fibers comprise polyamide fibers, polypropylene fibers, polyvinyl alcohol fibers, cellulose fibers, or glass fibers.

12. 12. The gypsum board of claim 11, wherein one or more of the gypsum slurry, the gypsum core, the first mat, or the second mat comprises 1 to 15 lbs / msf of reinforcing fibers.

13. 10. The gypsum board of claim 1, wherein the reinforcing fibers comprise plasma-treated or corona-treated reinforcing fibers.

14. 10. The gypsum board of claim 1, wherein the polymer foam comprises styrene butadiene copolymer, polyvinyl alcohol, styrene acrylic copolymer, polymeric microspheres, expandable microspheres, or hollow glass spheres.

15. 10. The gypsum board of claim 1, wherein the polymer foam comprises a dilute solution of Lipaton 8100.

16. 10. The gypsum board of claim 1, further comprising a polymer matrix layer uniformly distributed between the top of the gypsum layer and the second mat.

17. 17. The gypsum board of claim 16, wherein the polymer matrix layer is up to 20 lbs / msf.

18. The gypsum board of claim 1 , wherein the gypsum slurry is configured to generate a plurality of air bubbles on or within the gypsum layer.

19. 10. The gypsum board of claim 1, wherein the outer layer is glass mat, coated glass mat or paper, or any other facer that does not include a coating.

20. 1. A method for manufacturing gypsum board, comprising: forming a gypsum layer from a gypsum slurry, the gypsum layer comprising a gypsum slurry configured to improve one or more of strength, nail pull resistance, pull-out resistance, push-through resistance, or flexural strength of the gypsum board; Positioning a first mat on the bottom of the gypsum layer; and positioning a second mat on top of the gypsum layer.

21. A gypsum board, A gypsum core, one or more reinforcing fibers; a gypsum core comprising: a soap solution; and one or more gypsum layers comprising a gypsum slurry configured to improve one or more of the strength, nail pull resistance, pull-out resistance, push-through resistance, or flexural strength of the gypsum board; a first mat disposed on the bottom of the one or more gypsum layers; a second mat disposed on top of the one or more gypsum layers.

22. 22. The gypsum board of claim 21, wherein one or more of the gypsum slurry or the gypsum core further comprises the soap solution and the polymer foam in a predetermined mix ratio.

23. 23. The gypsum board of claim 22, wherein the polymer foam comprises a dilute solution of Lipaton 8100.

24. 22. The gypsum board of claim 21, wherein at least one of the one or more gypsum layers comprises a slate coat layer.

25. 25. The gypsum board of claim 24, wherein the slate coat layer is disposed between the gypsum board and the bottom of the one or more gypsum layers or between the gypsum board and the top of the one or more gypsum layers.

26. 22. The gypsum board of claim 21, wherein the first mat or the second mat includes a mat coating on a surface opposite the gypsum core, the mat coating penetrating a portion of the first mat.

27. 22. The gypsum board of claim 21, wherein the first mat or the second mat comprises a fibrous mat such that voids are not formed in the first mat or the second mat.

28. 22. The gypsum board of claim 21, wherein the first mat or the second mat comprises a glass mat or a paper sheet.

29. 30. The gypsum board of claim 28, wherein the glass mat includes a dispersant, a siloxane, and other ingredients, and wherein the glass mat is combined with the one or more reinforcing fibers of the gypsum core.

30. 30. The gypsum board of claim 28, wherein the paper sheet comprises starch, SIMP, and is combined with the one or more reinforcing fibers of the gypsum core.

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