Exterior sheathing panel with integrated air/water barrier membrane

Patent metadata

Field	Value
Publication number	US-10906271-B2
Application number	US-202016734867-A
Country	US
Kind code	B2
Filing date	Jan 6, 2020
Priority date	Mar 15, 2013
Publication date	Feb 2, 2021
Grant date	Feb 2, 2021

Abstract

An exterior sheathing cementitious panel which prevents water penetration and air leakage is provided. Methods for manufacturing exterior sheathing cementitious panels with a highly efficient integrated air/water barrier membrane are provided as well.

First claim

What is claimed is:

1. A method of manufacturing an exterior sheathing panel with an integrated air and water barrier membrane, the method comprising the following steps:
coating a cementitious panel comprising a cover sheet, wherein the cover sheet is a fibrous mat with an exterior facing surface on at least the exterior facing surface with an integrated air and water barrier membrane formulated with 30 to 70% by weight of a polymeric binder comprising a polyacrylate, polyurethane, silicone emulsion, polystyrene, styrene acrylic copolymer or any combination thereof; 20 to 50% by weight of calcium carbonate; 0.1 to 5% by weight of a wetting and leveling agent; and 0.1 to 5% by weight of a cross linker; and
conditioning the coated cementitious panel in an oven, wherein the coated cementitious panel is exposed to at least two different temperature zones, a first temperature zone and a second temperature zone, wherein the first temperature zone has a temperature lower than the second temperature zone.

2. The method of claim 1 , wherein the temperature in the first temperature zone is in the range from 100° F. to 140° F. and wherein the temperature in the second temperature zone is in the range from about 160° F. to 190° F.

3. The method of claim 1 , wherein the integrated air and water barrier membrane is applied by spray coating, roll coating and/or flood coating.

4. The method of claim 1 , wherein the method further comprises:
preparing a gypsum slurry;
sandwiching the gypsum slurry between two cover sheets; and
allowing the gypsum slurry to set, and thereby forming a cementitious panel.

5. The method of claim 1 , wherein the integrated air and water barrier membrane is applied to the cementitious panel in a wet thickness of 5-100 mils.

6. The method of claim 1 , wherein the integrated air and water barrier membrane is applied to the cementitious panel at a wet thickness calculated such that the application of the integrated air and water barrier membrane to the cementitious panel reduces water penetration through the cementitious panel by at least 50%.

7. The method of claim 1 , wherein the integrated air and water barrier membrane is applied to the cementitious panel at a wet thickness calculated such that the application of the integrated air and water barrier membrane to the cementitious panel reduces water penetration through the cementitious panel by 70-80%.

8. The method of claim 1 , wherein the method further comprises applying a sheet membrane over the integrated air and water barrier membrane after the integrated air and water barrier membrane is formed on the cementitious panel.

9. The method of claim 8 , wherein the sheet membrane is applied by laying, rolling, laminating, calendering and/or pressing.

10. The method of claim 1 , wherein the method further comprises embedding a standoff material in the air and water barrier membrane.

11. The method of claim 10 , wherein the standoff material includes one or more of the following: an open weave mesh, a pellet or a bead.

12. The method of claim 1 , wherein the fibrous mat comprises coated or uncoated fibers.

13. The method of claim 1 , wherein the cementitious panel comprises a cementitious core containing a calcium sulfate material, Portland cement or a mixture thereof.

14. The method of claim 1 , wherein the fibrous mat is woven or non-woven.

15. The method of claim 1 , wherein the fibrous mat comprises polymer fibers, mineral fibers or a combination thereof.

16. The method of claim 1 , wherein the integrated air and water barrier membrane further comprises at least one of the following additives: dispersant, defoamer, pigment, thickener, preservative, pH adjuster, emulsion stabilizer, or any combination thereof.

17. The method of claim 1 , wherein the fibrous mat is non-woven and comprises fibers, and the fibers in the fibrous mat are bound together by a mat binder.

18. The method of claim 1 , wherein the fibrous mat comprises glass fibers, wherein the glass fibers in the fibrous mat are bound together by a mat binder, and wherein the mat binder comprises one or more from the following: urea formaldehyde, melamine formaldehyde, stearated melamine formaldehyde, polyester, acrylics, polyvinyl acetate, urea formaldehyde or melamine formaldehyde modified or blended with polyvinyl acetate or acrylic, a styrene acrylic polymer, or any combination thereof.

19. The method of claim 1 , wherein the wetting and leveling agent comprises at least one of the following: sulfosuccinate, polyether modified siloxane, urea modified polyurethane, or modified urea ammonium salt of an acrylate copolymer.

20. The method of claim 1 , wherein the cross linker comprises at least one of the following: zinc oxide, zinc metal ions, stabilized ammonium zirconium carbonate containing anionic hydroxylated zirconium polymers, or epoxy functional silane.

Assignees

• United States Gypsum Co
• Tremco Inc

Inventors

• Shake Michael P
• Negri Robert H
• Mcknight Paula
• Shipp Paul
• Ullett James M
• Kenny Timothy G
• Link Brett R
• Hernandez Pamela
• Schulte Kristin
• Marimpietri Dante
• Sovey Casey
• Mohammad Muneer
• Cremona Dominic
• Zerucha Ellen
• Stinson Scottie Lee

Classifications

• E04C2/288

  composed of insulating material and concrete, stone or stone-like material · CPC title

• E04B1/62

  Insulation or other protection; Elements or use of specified material therefor (chemical compositions C01 - C11; implements for applying insulation or sealings E04F21/00; buildings to withstand, or to provide protection against, external undesired influences E04H9/00; sealing pipes in walls or partitions F16L5/02; shielding against dangerous radiation G21F) · CPC title

• C04B28/02

  containing hydraulic cements other than calcium sulfates · CPC title

• B32B13/14

  next to a fibrous or filamentary layer · CPC title

• B32B13/04 Primary

  comprising such {water setting} substance as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a glass layer B32B17/06)} · CPC title