Water barrier exterior sheathing panel

Patent metadata

Field	Value
Publication number	US-11518141-B2
Application number	US-201916585799-A
Country	US
Kind code	B2
Filing date	Sep 27, 2019
Priority date	Nov 1, 2018
Publication date	Dec 6, 2022
Grant date	Dec 6, 2022

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 sheet are also provided. An exterior sheathing system employing the exterior sheathing cementitious panel is provided.

First claim

We claim:

1. A method of making exterior sheathing panel from a gypsum panel or a cement panel, comprising:
providing a set cementitious panel comprising a set cementitious core selected from:
a set gypsum panel comprising a set gypsum panel core layer, wherein the set gypsum panel core layer comprises greater than 75 weight % calcium sulfate dihydrate, and a gypsum panel fibrous mat attached as a cover sheet to the set gypsum panel core layer wherein the cover sheet is embedded in the set gypsum panel core layer, wherein the gypsum panel fibrous mat comprises at least one of polymer fibers, glass fibers, mineral fibers or a combination thereof, wherein the gypsum panel fibrous mat has an absence of paper fibers, and wherein the gypsum panel fibrous mat has an absence of cellulose, or
a cement panel comprising a set cement panel cementitious core layer, wherein the cement panel cementitious core layer is made from setting an aqueous mixture containing 50 to 100 wt. % reactive powder on a dry basis, wherein the set reactive powder comprises at least 10 weight percent set hydraulic cement and at most 75 wt. % calcium sulfate dihydrate,

providing an air/water barrier sheet which overlays the cementitious panel and is attached to the cementitious panel, wherein the air/water barrier sheet comprises an air/water barrier layer comprising any of a metal sheet, coated metal sheet, polymer sheet, or combinations thereof,
wherein the air/water barrier sheet optionally has an air/water barrier sheet fibrous mat layer attached to the air/water barrier layer, wherein the air/water barrier sheet fibrous mat, if present, comprises at least one of polymer fibers, glass fibers, mineral fibers or a combination thereof, wherein the air/water barrier sheet fibrous mat has an absence of paper fibers, and wherein the air/water barrier sheet fibrous mat has an absence of cellulose,
locating an adhesive layer between the cementitious panel and the air/water barrier layer,
wherein the adhesive layer attaches an entire surface of a side of the air/water barrier sheet to the gypsum panel fibrous mat embedded on a side of the set gypsum panel facing the air/water barrier sheet, or
wherein the adhesive layer attaches an entire surface of a side of the air/water barrier sheet to a side of the cement panel facing the air/water barrier sheet, wherein the adhesive layer is located directly on the set cementitious core layer between the cement panel and the air/water barrier layer and the air/water barrier sheet is not embedded in the cementitious core layer, or
wherein the adhesive layer attaches an entire surface of a side of the air/water barrier layer directly to the air/water barrier sheet fibrous mat layer when the air/water barrier sheet fibrous mat layer is embedded in the set cement cementitious core layer,

wherein said air/water barrier layer is individually attached to a respective said set cementitious panel, wherein each respective said air/water barrier sheet entirely covers a side of the respective set cementitious panel,
wherein the air/water barrier sheet has a perm rating in the range of less than or equal to 0.15,
wherein the metal sheet and metal sheet of the coated metal sheet have a thickness between 0.0002 and 0.003 inches, wherein the perm rating is according to a desiccant method with Procedure A of ASTM E96 (2016).

2. The method of claim 1 , wherein the set cementitious panel is the set cement panel, wherein the adhesive layer attaches the entire surface of the side of the air/water barrier sheet to the side of the cement panel facing the air/water barrier sheet, wherein the adhesive layer is located directly on the set cementitious core layer between the cement panel and the air/water barrier layer and the air/water barrier sheet is not embedded in the cementitious core layer.

3. The method of claim 1 , wherein the adhesive layer is applied to the fibrous mat face on the fibrous mat-faced cementitious panel having the set cementitious core to form the laminate having the adhesive layer; and then the air/water barrier sheet is applied to contact the adhesive layer on the fibrous mat face on the side of the fibrous mat-faced cementitious panel.

4. The method of claim 1 , wherein the adhesive layer is applied to the air/water barrier sheet to form the laminate having the adhesive layer; and then the laminate is applied to the cementitious panel having the set cementitious core to contact the adhesive layer with the fibrous mat face on the side of the cementitious panel.

5. A method of making exterior sheathing panel comprising a cement panel,
wherein the cement panel has a cementitious core layer that is made from an aqueous mixture containing 50 to 100 wt. % reactive powder on a dry basis, wherein the reactive powder comprises hydraulic cement and at most 75 wt. % calcium sulfate dihydrate, wherein the cementitious core layer comprises more than 30 wt. % hydraulic cement, comprising:
providing an air/water barrier sheet comprising an outer layer of an air/water barrier sheet fibrous mat layer attached to an air/water barrier layer,
wherein the air/water barrier sheet fibrous mat comprises at least one of polymer fibers, glass fibers, mineral fibers or a combination thereof, wherein the air/water barrier sheet fibrous mat has an absence of paper fibers, and wherein the air/water barrier sheet fibrous mat has an absence of cellulose,
wherein the air/water barrier layer consists of a metal sheet,
feeding the air/water barrier sheet onto a moving surface of the manufacturing line with the air/water barrier sheet fibrous mat facing up away from the moving surface,
feeding a scrim to overlay the air/water barrier sheet fibrous mat facing up away from the moving surface;
then depositing the aqueous mixture on the air/water barrier sheet fibrous mat and the scrim while the air/water barrier sheet and the scrim are moving on the moving surface, wherein the aqueous mixture penetrates the fibrous mat and embeds the scrim, and
then allowing the aqueous mixture to set to form a panel precursor and cutting the panel precursor to a desired length to form the exterior sheathing panels having the cement panel core, wherein each respective said air/water barrier sheet is individually attached to only a single respective said cementitious panel, wherein each respective said air/water barrier sheet entirely covers a side of the respective cementitious panel,
wherein an adhesive layer is located between the cementitious core and the air/water barrier layer,
wherein the adhesive layer attaches an entire surface of a side of the air/water barrier layer to the air/water barrier sheet fibrous mat layer when the air/water barrier sheet fibrous mat layer is embedded in the cement core layer,
wherein each exterior sheathing panel has one said air/water barrier sheet attached to only a single respective said cementitious panel, wherein each respective said air/water barrier sheet entirely covers a side of the respective cementitious panel,
wherein the air/water barrier sheet has a perm rating in the range of less than or equal to 0.15, wherein the metal sheet is adhered by the layer of adhesive to the at least one fibrous mat-faced surface of the fibrous mat-faced cementitious panel,
wherein the metal sheet has a thickness between 0.0002 and 0.005 inches, wherein the perm rating is according to a desiccant method with Procedure A of ASTM E96 (2016).

6. The method of claim 5 , wherein the air/water barrier sheet is pre-made to have the adhesive layer between the air/water barrier layer and the air/water barrier sheet fibrous mat layer.

7. The method of claim 5 , wherein the air/water barrier sheet is made on a manufacturing line for the method of making exterior sheathing panel by applying adhesiv

Assignees

• United States Gypsum Co

Inventors

• Donelan Jeffrey W
• Shake Michael P
• Rao Ajith M
• Ullett James M
• Peng Yanfei

Classifications

• B32B2607/00

  Walls, panels · CPC title

• B32B2315/08

  Glass · CPC title

• B32B5/022 Primary

  Non-woven fabric · CPC title

• B32B2262/105

  Ceramic fibres · CPC title

• B32B2307/732

  Dimensional properties · CPC title