Freeform, additive manufacturing equipment, processes and products, including residential, commercial and other buildings. A movable extruder places extrudate that solidifies in open space to create scaffolding or skeletons of buildings and other products. Elongated extrudate elements are fused to each other or connected by other means to form a cellular structure. Filler material such as polymeric insulating foam may simultaneously or thereafter be placed within the cellular structure to contribute desired strength, rigidity, insulative, barrier or other properties. Finish materials may also be applied.

Freeform, additive manufacturing equipment, processes and products, including residential, commercial and other buildings. A movable extruder places extrudate that solidifies in open space to create scaffolding or skeletons of buildings and other products. Elongated extrudate elements are fused to each other or connected by other means to form a cellular structure. Filler material such as polymeric insulating foam may simultaneously or thereafter be placed within the cellular structure to contribute desired strength, rigidity, insulative, barrier or other properties. Finish materials may also be applied.

The invention relates to a fibrous mat facer for preparing a gypsum board, to a gypsum board comprising said mat facer and to a system comprising said gypsum board. The fibrous mat comprises at least one ply of a non-woven fabric, and a binder composition, wherein the binder composition represents from 10 to 40 wt % of the total weight of the mat. The binder composition comprises a copolymer comprising a co-monomer unit of a vinyl ester of an alpha branched aliphatic monocarboxylic acid, said copolymer being present in an amount from 25 to 100 wt % of the binder composition weight.

The invention relates to a fibrous mat facer for preparing a gypsum board, to a gypsum board comprising said mat facer and to a system comprising said gypsum board. The fibrous mat comprises at least one ply of a non-woven fabric, and a binder composition, wherein the binder composition represents from 10 to 40 wt % of the total weight of the mat. The binder composition comprises a copolymer comprising a co-monomer unit of a vinyl ester of an alpha branched aliphatic monocarboxylic acid, said copolymer being present in an amount from 25 to 100 wt % of the binder composition weight.

A carrier material has a resin layer arranged on a side of the carrier material. The resin layer includes a formaldehyde resin, a polymer selected from a group containing polyacrylates, polyepoxides, polyesters, polyurethanes, and long-chain silanols, and at least one silane-containing compound of general formula (I), R.sub.a SiX.sub.(4-a), and/or the hydrolysis product thereof, where X is H, OH, or a hydrolyzable residue selected from the group comprising halogen, alkoxy, carboxy, amino, monoalkylamino or dialkylamino, aryloxy, acyloxy, alkylcarbonyl; R is a non-hydrolyzable organic residue R selected from the group comprising alkyl, aryl, alkenyl, substituted and unsubstituted alkynyl, cycloalkyl, which can be interrupted by O or NH; and where R can have a functional group Q selected from a group containing a hydroxy, ether, amino, monoalkylamino, dialkylamino, anilino, amide, carboxy, mercapto, alkoxy, aldehyde, alkylcarbonyl, epoxide, alkenyl, alkynyl, acryl, acryloxy, methacryl, methacryloxy, cyano, and isocyano group, and a is 0-3.

Freeform, additive manufacturing equipment, processes and products, including residential, commercial and other buildings. A movable extruder places extrudate that solidifies in open space to create scaffolding or skeletons of buildings and other products. Elongated extrudate elements are fused to each other or connected by other means to form a cellular structure. Filler material such as polymeric insulating foam may simultaneously or thereafter be placed within the cellular structure to contribute desired strength, rigidity, insulative, barrier or other properties. Finish materials may also be applied.

Freeform, additive manufacturing equipment, processes and products, including residential, commercial and other buildings. A movable extruder places extrudate that solidifies in open space to create scaffolding or skeletons of buildings and other products. Elongated extrudate elements are fused to each other or connected by other means to form a cellular structure. Filler material such as polymeric insulating foam may simultaneously or thereafter be placed within the cellular structure to contribute desired strength, rigidity, insulative, barrier or other properties. Finish materials may also be applied.

The web frame is a bonded assembly of panels and porous blanket layers, separated by an arrangement of isolated spacers. The panels and spacers are covered with a bonding means. A coating covers inner surfaces of the panels and spacers. The porous blanket is compressed and pinned between these panels, by spacers that are arranged as isolated nodes or columns The spacers have sharpened ends that penetrate the blanket and connect with the opposing panel. The web frame assembly provides thermal and sound insulation for buildings and other solid objects. These web frames are lightweight, durable, and permeable. Capillaries and passages throughout the panels and fibers of the blanket allow passage of moisture and air, thereby assisting in the management of condensation within the web frame.

The web frame is a bonded assembly of panels and porous blanket layers, separated by an arrangement of isolated spacers. The panels and spacers are covered with a bonding means. A coating covers inner surfaces of the panels and spacers. The porous blanket is compressed and pinned between these panels, by spacers that are arranged as isolated nodes or columns The spacers have sharpened ends that penetrate the blanket and connect with the opposing panel. The web frame assembly provides thermal and sound insulation for buildings and other solid objects. These web frames are lightweight, durable, and permeable. Capillaries and passages throughout the panels and fibers of the blanket allow passage of moisture and air, thereby assisting in the management of condensation within the web frame.

An improved water-resistant gypsum product prepared with a high-viscosity siloxane is provided. A fuel-efficient method for making the product and reducing the amount of siloxane dust released is provided as well.