Paper and/or mat-faced gypsum board is prepared by applying a relatively
thin coating of aqueous gypsum slurry containing a polyvinyl alcohol
binder to one or two facer sheets. The polyvinyl alcohol binder provides
adequate adhesion between the set gypsum core and the adjacent facer
sheet(s) without the need for starch or other conventional binders. In
one embodiment, polyvinyl alcohol is concentrated in one or more regions
of the core adjacent to the facer sheet(s). In another embodiment,
polyvinyl alcohol is applied to an aqueous gypsum slurry used to form the
bulk core, such that the polyvinyl alcohol is present throughout the
core.
