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US 12,734,724 B2Granted
Air and water barrier building panels
AssigneeGold Bond Building Products, LLC
InventorsBrian G. Randall, Joseph J. Bailey, Eli Stav, Brian Bland, Gene Whittington, R. G. Iyer
Life of this patent
Estimating the term…
Abstract
A method for improving the air and/or water barrier performance of a building panel is disclosed. The building panel may be a gypsum board or cement board. In particular, the board may have improved resistance to bulk water penetration or permeation while maintaining breathability with respect to water vapor.
Claims21
A method of making a gypsum panel having improved air and water barrier performance, the method comprising:
- providing a first nonwoven facing material,
- providing a board slurry on the first nonwoven facing material, the board slurry comprising a binder, the binder comprising a starch, the board slurry penetrating the first nonwoven facing material, the board slurry forming a board core, the board core being free of polyvinyl alcohol,
- providing a second facing material on the board slurry, and
- applying a hydrophobic material to the first nonwoven facing material prior to providing the first nonwoven facing material, wherein the hydrophobic material is applied on a side of the first nonwoven facing material opposite a side adjacent the board slurry and forms a coating thereon, wherein the hydrophobic material penetrates the first nonwoven facing material, wherein the hydrophobic material is present in an amount of about 0.01 wt. % to about 10.0 wt. % based on the weight of the first nonwoven facing material and wherein the coating consists essentially of a polysiloxane comprising methylhydrogen polysiloxane or a polydialkylsiloxane,
- wherein the total amount of lignosulfonates in the board slurry is 0.1 wt. % or less.
2 more elements
A method of making a gypsum panel having improved air and water barrier performance, the method comprising:
- providing a first nonwoven facing material,
- providing a board slurry on the first nonwoven facing material, the board slurry forming a board core, the board core being free of polyvinyl alcohol, and
- providing a second facing material on the board slurry,
- wherein a hydrophobic material is applied to the first nonwoven facing material and forms a coating thereon, wherein the hydrophobic material is applied on a side of the first nonwoven facing material opposite a side adjacent the board slurry, wherein the hydrophobic material penetrates the first nonwoven facing material, wherein the hydrophobic material is present in an amount of about 0.01 wt. % to about 10.0 wt. % based on the weight of the first nonwoven facing material and wherein the coating consists essentially of a polysiloxane comprising methylhydrogen polysiloxane or a polydialkylsiloxane, wherein a polymeric coating is not applied on the side of the first nonwoven facing material adjacent the board slurry,
- wherein the application of the hydrophobic material to the first nonwoven facing material forms a hydrophobic facing material, wherein fly ash is not applied to form the hydrophobic facing material,
- wherein the total amount of lignosulfonates in the board slurry is 0.1 wt. % or less.
3 more elements
Dependencies are inferred from the claim text.