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US 2017/0282510 A1Published application
Building board having high fastener sealability
AssigneeCertainTeed Gypsum, Inc.
InventorsJeffrey H. PEET, Artemis Agelaridou-Twohig, Michael J. LEMBERGER, Todd P. DiNoia, Jean-Philippe Ndobo-Epoy
Life of this patent
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Abstract
A building board, particularly a gypsum board, can have a high fastener sealability if protected by the combination of thin layers of an extruded polymer film and a thermoplastic coating layer. The combination of extruded polymer film and thermoplastic coating layer is designed such that the gypsum board can also tolerate overdriven fasteners, thus exceeding the requirements of ASTM D1970-15.
Claims20
A building board, comprising:
- a cementitious layer sandwiched between a first fiber mat and a second fiber mat;
- an extruded polymer film overlying the first fiber mat and/or the second fiber mat, the extruded polymer film having a thickness in a range of at least 5 microns and not greater than 130 microns;
- and
- a thermoplastic coating layer directly overlying the extruded polymer film, the thermoplastic coating layer having a thickness in a range of at least 30 microns and not greater than 260 microns,
- wherein the building board passes fastener sealability testing according to a modified ASTM D1970, the fastener sealability testing employing a fastener being 635 microns overdriven in the building board for a period of three days at 22° C.
2 more elements
A method for manufacturing a building board, comprising:
- providing an extruded polymer film having a thickness in a range of at least 5 microns and not greater than 130 microns and attaching the polymer film with an adhesive onto a first surface of a first fiber-mat;
- applying a cementitious layer on top of a second surface of the first fiber-mat, the second surface being opposite to the first surface of the first fiber-mat;
- applying a second fiber mat on top of the cementitious layer to obtain a fiber-mat sandwiched cementitious layer composite;
- drying the fiber-mat sandwiched cementitious layer composite;
- and
- applying a thermoplastic polymeric coating layer onto an outer surface of the extruded polymer film,
- wherein the building board passes fastener sealability testing according to a modified ASTM D1970-15, the modified testing comprising employing a fastener being 635 microns overdriven in the building board for a period of 3 days at 22° C.
4 more elements
Dependencies are inferred from the claim text.