Gypsum panels, systems, and methods

Patent metadata

Field	Value
Publication number	US-10077552-B2
Application number	US-201715668146-A
Country	US
Kind code	B2
Filing date	Aug 3, 2017
Priority date	Feb 3, 2015
Publication date	Sep 18, 2018
Grant date	Sep 18, 2018

Abstract

Gypsum panels, sheathing systems, and methods of making and using the same are provided. A gypsum panel includes a gypsum core associated with a first fiberglass mat having a continuous barrier coating, the coating penetrating a portion of the first fiberglass mat opposite the gypsum core, wherein gypsum penetrates a remaining fibrous portion of the first fiberglass mat such that voids in the first fiberglass mat are substantially eliminated. A building sheathing system includes at least two gypsum panels and a seaming component to provide a seam at an interface between the gypsum panels.

First claim

What is claimed is:

1. A method of constructing a building sheathing system, comprising:
installing at least two gypsum panels having an interface therebetween to form an external building sheathing; and
applying a seaming component at the interface between the at least two gypsum panels,
wherein, in the absence of any externally applied barrier product, other than the seaming component:
the system passes a hydrostatic head test against water leakage, as measured by AATCC 127-2008,
the system displays no water leaks when measured according to ICC Evaluation Service Acceptance Criteria 212,
the system passes ICC Evaluation Service Acceptance Criteria 310, and/or
the system displays no water leaks when measured according to ASTM E331 wall assembly test,

wherein the at least two gypsum panels each comprise a gypsum core associated with a first fiberglass mat having a continuous barrier coating that comprises a plurality of pin holes that provide for water vapor transmission across the coating, the coating penetrating a portion of the first fiberglass mat opposite the gypsum core, wherein gypsum of the gypsum core penetrates a remaining fibrous portion of the first fiberglass mat such that voids in the first fiberglass mat are substantially eliminated, and
wherein the gypsum core of each gypsum panel comprises a first gypsum layer that at least partially penetrates the remaining fibrous portion of the first fiberglass mat, the first gypsum layer being formed by a gypsum slurry that comprises a wetting agent in an amount effective to bring a slurry surface tension of the first gypsum layer from about 30 dyne/cm to about 55 dyne/cm.

2. The method of claim 1 , wherein the gypsum core of each gypsum panel comprises a first gypsum layer that at least partially penetrates the remaining fibrous portion of the first fiberglass mat, the first gypsum layer having a slurry density of about 88 pcf to about 98 pcf.

3. The method of claim 1 , wherein the first gypsum layer is present in an amount from about 5 percent to about 20 percent, by weight, of the gypsum core.

4. The method of claim 1 , wherein the seaming component comprises tape or a bonding material.

5. The method of claim 4 , wherein the seaming component comprises a bonding material selected from the group consisting of synthetic stucco plasters, cement plasters, synthetic acrylics, sand-filled acrylics, solvent-based acrylics, solvent-based butyls, polysulfides, polyurethanes, silicones, silyl-modified polymers, water-based latexes, EVA latexes, and acrylic latexes.

6. The method of claim 1 , wherein the system passes AATCC hydrostatic head test method 127-2008 for a 22-inch head of water directly over the seaming component at the interface between the at least two gypsum panels, with no leaks after 5 hours.

7. The method of claim 1 , wherein the system has a water vapor permeance of at least 20 inch-pound units, as measured by ASTM E96 wet cup method.

8. The method of claim 1 , wherein the system displays an air leakage rate of less than 0.04 cfm/ft 2 at 1.57 lbs/ft 2 , when measured according to ASTM E2357.

9. The method of claim 1 , wherein the system is substantially free of any externally-applied fabric membrane, liquid coating, or self-adhered membrane.

10. A method of constructing a building sheathing system, comprising:
installing at least two gypsum panels having an interface therebetween to form an external building sheathing, each gypsum panel comprising a gypsum core associated with a first fiberglass mat having a continuous barrier coating that comprises a plurality of pin holes that provide for water vapor transmission across the coating, the coating penetrating a portion of the first fiberglass mat opposite the gypsum core, wherein gypsum of the gypsum core penetrates a remaining fibrous portion of the first fiberglass mat such that voids in the first fiberglass mat are substantially eliminated; and
applying a seaming component at the interface between the at least two gypsum panels,
wherein the system is substantially free of any externally-applied fabric membrane, liquid coating, or self-adhered membrane, and
wherein the gypsum core of each gypsum panel comprises a first gypsum layer that at least partially penetrates the remaining fibrous portion of the first fiberglass mat, the first gypsum layer being formed by a gypsum slurry that comprises a wetting agent in an amount effective to bring a slurry surface tension of the first gypsum layer from about 30 dyne/cm to about 55 dyne/cm.

11. The method of claim 10 , wherein the gypsum core of each gypsum panel comprises a first gypsum layer that at least partially penetrates the remaining fibrous portion of the first fiberglass mat, the first gypsum layer having a slurry density of about 88 pcf to about 98 pcf.

12. The method of claim 10 , wherein the first gypsum layer is present in an amount from about 5 percent to about 20 percent, by weight, of the gypsum core.

13. The method of claim 10 , wherein the seaming component comprises tape or a bonding material.

14. The method of claim 13 , wherein the seaming component comprises a bonding material selected from the group consisting of synthetic stucco plasters, cement plasters, synthetic acrylics, sand-filled acrylics, solvent-based acrylics, solvent-based butyls, polysulfides, polyurethanes, silicones, silyl-modified polymers, water-based latexes, EVA latexes, and acrylic latexes.

15. The method of claim 10 , wherein the system passes AATCC hydrostatic head test method 127-2008 for a 22-inch head of water directly over the seaming component at the interface between the at least two gypsum panels, with no leaks after 5 hours.

16. The method of claim 10 , wherein the system has a water vapor permeance of at least 20 inch-pound units, as measured by ASTM E96 wet cup method.

17. The method of claim 10 , wherein the system displays an air leakage rate of less than 0.04 cfm/ft 2 at 1.57 lbs/ft 2 , when measured according to ASTM E2357.

Assignees

• Georgia Pacific Gypsum Llc

Inventors

• Thomas Vincent B
• Bradford Rochelle
• Sanders Christopher J
• Teng Yi-Hsien Harry

Classifications

• C03C25/42

  Coatings containing inorganic materials · CPC title

• C04B14/42

  Glass · CPC title

• E04C2/246 Primary

  combinations of materials fully covered by E04C2/16 and E04C2/20 · CPC title

• C03C25/1095

  to obtain coated fabrics · CPC title

• E04C2/20

  of plastics · CPC title