Building boards with increased surface strength
AssigneeCertainTeed Gypsum, Inc.
InventorsRobin Daniel Fisher, Devang Umesh Khariwala, Jeffrey Hamilton Peet, Peter Mayer
Life of this patent
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Abstract
Disclosed is a building board construction with increased surface strength. More specifically, increased nail pull strength is achieved via the application of an external surface coating. The surface coating is ideally applied to a paper faced gypsum building board. In one possible embodiment, the coating is formed from a water soluble polymer.
Claims19
A composite building board with enhanced nail pull strength, the composite building board comprising:
- first and second paper liners each having an interior face, the first paper liner having an exterior face forming an outer face of the building board;
- a set plaster core positioned between and bonded with the interior face of the first paper liner and the interior face of the second paper liner, the set plaster core formed from a cementitious slurry of predominantly calcium sulfate hemi-hydrate, the set plaster core being formed with a plurality of internal voids, the internal voids functioning to decrease the overall weight of the building board;
- and
- a spray coating of a coating polymer applied directly to the exterior face of the first paper liner, the spray coating having a tensile modulus above 500 psi and an elongation at break of greater than 500% at room temperature and improving a nail pull strength of the building board relative to an identical building board without the spray coating.
A composite building board with enhanced nail pull strength, the composite building board comprising:
- an exterior paper face forming an outer face of the building board;
- a set plaster core positioned beneath the exterior paper face, the set plaster core formed from a cementitious slurry of predominantly calcium sulfate hemi-hydrate;
- and
- a polymer-based spray coating or a coating polymer applied directly to the exterior paper face of the building board, the spray coating having a tensile modulus above 500 psi and an elongation at break of greater than 500% at room temperature and improving a nail pull strength of the building board relative to an identical building board without the spray coating by at least 10% as compared to an identical building board without the polymer-based spray coating.
A composite building board with enhanced nail pull strength, the composite building board comprising:
- an exterior paper face;
- a set plaster core positioned beneath the exterior paper face, the exterior paper face facing away from the set plaster core, the set plaster core formed from a cementitious slurry of predominantly calcium sulfate hemi-hydrate, and
- a polymer-based spray coating of a coating polymer applied directly to the exterior paper face of the building board in a non-uniform manner, the spray coating having a tensile modulus above 500 psi and an elongation at break of greater than 500% at room temperature and improving a nail pull strength of the building board relative to an identical building board without the spray coating.
Dependencies are inferred from the claim text.