A bond is created between a gypsum matrix formed from an aqueous acidic
gypsum slurry comprising a monomer mixture. The monomer mixture is
composed of a monomer having acidic functionality and a monomer having
hydroxyl or amine functionality. A silane-based sizing composition is
coated onto glass fibers causing a cross-linking network of silane and
monomer mixture to form during curing of the gypsum board. Hydrophilic
water extraction at the gypsum matrix-sizing interface reduces void
formation and promotes bonding with the crosslinked monomer mixture and
growth of smaller gypsum crystals within larger crystals in
microstructurally identifiable regions adjacent to the glass fiber. A
bond is created between a gypsum matrix formed from an aqueous acidic
gypsum slurry comprising a monomer mixture. The monomer mixture is
composed of a monomer having acidic functionality and a monomer having
hydroxyl or amine functionality. A silane-based sizing composition is
coated onto glass fibers causing a cross-linking network of silane and
monomer mixture to form during curing of the gypsum board. Hydrophilic
water extraction at the gypsum matrix-sizing interface reduces void
formation and promotes bonding with the crosslinked monomer mixture and
growth of smaller gypsum crystals within larger crystals in
microstructurally identifiable regions adjacent to the glass fiber.
Alternatively, the silane based sizing composition has branched chains
that diffuse into a wet gypsum mix containing the monomer mixture. During
gypsum cure, the diffusion and crosslinking of monomer mixture triggers
formation of interpenetrating pseudo polymeric networks within a
microstructurally identifiable region adjacent to the glass fiber. Bonds
formed between the gypsum matrix and the silane based sizing composition
increase the strength, flexure resistance and nail pull out resistance of
the gypsum board.