A process for making an improved gypsum/wood fiber board is described.
Products resulting from the process are also described. The process
comprises adding a diisocyanate, specifically
methylenediphenyldiisocyanate (MDI) to an aqueous slurry of calcium
sulfate material and cellulosic fibers, where the MDI is added as an
emulsion stable in the conditions in which the slurry is maintained. The
process further includes passing the MDI containing slurry onto a flat
porous forming surface to form a filter cake; removing a substantial
portion of the water from the filter cake through the porous surface;
pressing the filter cake to form a board and remove additional water; and
drying the board to remove the remaining free water.