# US 2019/0376286 A1 · Gypsum Panels, Systems, and Methods > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0376286 A1 - Document ID: US20190376286A1 - Status: Published application - Kind: A1 - Application number: 16/550,356 - Filed: 2019-08-26 - Published: 2019-12-12 - Earliest claimed: 2015-02-03 - Assignees: Georgia-Pacific Gypsum LLC - Applicants: Georgia-Pacific Gypsum LLC - Inventors: Vincent B. Thomas; Rochelle Bradford; Christopher J. Sanders; Yi-Hsien Harry Teng - Web page: https://patentgrep.com/patent/US20190376286A1 ## CPC - E04C 2/246: {combinations of materials fully covered by E04C2/16 and E04C2/20} - B32B 13/12: of synthetic resin - B32B 13/14: next to a fibrous or filamentary layer - C03C 25/1025: to obtain fibres used for reinforcing cement-based products - C03C 25/1095: to obtain coated fabrics - C03C 25/26: Macromolecular compounds or prepolymers - C03C 25/42: Coatings containing inorganic materials - C03C 25/47: containing particles, fibres or flakes, e.g. in a continuous phase - C04B 11/00: Calcium sulfate cements - C04B 14/42: Glass - C04B 28/14: containing calcium sulfate cements {(gypsum-paper plates E04C)} - E04B 1/665: {Sheets or foils impervious to water and water vapor} - E04B 1/6803: {Joint covers (E04B1/6815 takes precedence)} - E04C 2/04: of concrete or other stone-like material; of asbestos cement; {of cement and other mineral fibres}(E04C2/26 takes precedence; material or manufacture B28, C04) - E04C 2/043: {of plaster (E04C2/049 takes precedence)} - E04C 2/06: reinforced - E04C 2/16: of fibres, chips, vegetable stems, or the like - E04C 2/20: of plastics - E04C 2/24: laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 - E04C 2/26: composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups {(of cement and mineral fibres E04C2/04)} - E04C 2/28: combinations of materials fully covered by groups E04C2/04 and E04C2/08 - E04C 2/34: composed of two or more spaced sheet-like parts (E04C2/32 takes precedence; spacers for cavity walls E04B2/44) - G01N 15/0806: {Details, e.g. sample holders, mounting samples for testing} - B28B 1/08: by vibrating or jolting {(of moulding sand B22C15/10; of concrete in general E04G21/063)} - B28B 1/30: by applying the material on to a core or other moulding surface to form a layer thereon (to form a permanent layer B28B19/00) - B32B 2255/26: Polymeric coating - B32B 2260/021: Fibrous or filamentary layer - B32B 2260/023: Two or more layers - B32B 2260/044: Water-setting substance, e.g. concrete, plaster - B32B 2262/101: Glass fibres - B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant - B32B 2307/724: Permeability to gases, adsorption - B32B 2307/7246: Water vapor barrier - B32B 2307/7265: Non-permeable - B32B 2307/73: Hydrophobic - B32B 2419/00: Buildings or parts thereof - B32B 2607/00: Walls, panels - C04B 2111/00612: {as one or more layers of a layered structure} - G01N 2015/086: {of films, membranes or pellicules} - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - C03C: CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001}) - G01N: INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES (measuring or testing apparatus or processes other than immunoassay, involving enzymes or microorganisms C12M, C12Q) - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) ## Abstract Gypsum panels, sheathing systems, and methods of making and using the same are provided. A gypsum panel includes a gypsum core associated with a first fiberglass mat having a continuous barrier coating, the coating penetrating a portion of the first fiberglass mat opposite the gypsum core, wherein gypsum penetrates a remaining fibrous portion of the first fiberglass mat such that voids in the first fiberglass mat are substantially eliminated. A building sheathing system includes at least two gypsum panels and a seaming component to provide a seam at an interface between the gypsum panels. ## Claims ### Claim 1 A method of making a gypsum panel, comprising: depositing a gypsum slurry onto a surface of a first fiberglass mat opposite a continuous barrier coating that penetrates a portion of the first fiberglass mat; and allowing the gypsum slurry to set to form a gypsum core, wherein the gypsum slurry penetrates a remaining fibrous portion of the first fiberglass mat such that voids in substantially all of an interstitial volume of the first fiberglass mat that is not filled by the coating are substantially eliminated, and wherein the gypsum panel passes a hydrostatic head test against water leakage, as measured by AATCC 127-2008. ### Claim 2 (depends on 1) The method of claim 1, wherein: depositing the gypsum slurry comprises depositing a first gypsum slurry onto the surface of the first fiberglass mat, the first gypsum slurry having a density of from about 88 pcf to about 98 pcf, and allowing the gypsum slurry to set comprises allowing the first gypsum slurry to set to form at least a portion of the gypsum core. ### Claim 3 (depends on 2) The method of claim 2, wherein the first gypsum slurry comprises a wetting agent in an amount effective to reduce a surface tension of the first gypsum slurry to from about 30 dyne/cm to about 55 dyne/cm. ### Claim 4 (depends on 3) The method of claim 3, wherein the wetting agent is selected from a group consisting of surfactants, superplasticisers, dispersants, agents containing surfactants, agents containing superplasticisers, agents containing dispersants, and combinations thereof. ### Claim 5 (depends on 3) The method of claim 3, wherein the wetting agent is a surfactant that is present in the first gypsum slurry in an amount of about 0.05 percent to about 1 percent, by weight. ### Claim 6 (depends on 2) The method of claim 2, wherein the first gypsum slurry comprises a hydrophobic additive selected from the group consisting of wax, silicone, siloxane, silane, and combinations thereof. ### Claim 7 (depends on 2) The method of claim 2, wherein the first gypsum slurry comprises a polymer binder. ### Claim 8 (depends on 2) The method of claim 2, wherein the first gypsum slurry is deposited in an amount of from about 5 percent to about 20 percent, by weight, of the gypsum core. ### Claim 9 (depends on 2) The method of claim 2, further comprising mechanically vibrating at least the first fiberglass mat having the first gypsum slurry deposited thereon to effect penetration of the gypsum slurry into the remaining fibrous portion of the first fiberglass mat. ### Claim 10 (depends on 2) The method of claim 2, wherein: depositing the gypsum slurry further comprises depositing a second gypsum slurry onto the first gypsum slurry, having a slurry density of from 76 pcf to 93 pcf, and allowing the gypsum slurry to set comprises allowing the second gypsum slurry to set to form at least a remaining portion of the gypsum core. ### Claim 11 (depends on 1) The method of claim 1, wherein the gypsum panel has a water vapor permeance of at least 10 inch-pound units, as measured by ASTM E96 wet cup method. ### Claim 12 (depends on 1) The method of claim 1, wherein the gypsum panel has a water vapor permeance of at least 30 inch-pound units, as measured by ASTM E96 wet cup method. ### Claim 13 (depends on 1) The method of claim 1, wherein the gypsum core fills at least 95 percent of the interstitial volume. ### Claim 14 (depends on 1) The method of claim 1, wherein the gypsum core fills at least 98 percent of the interstitial volume. ### Claim 15 (depends on 1) The method of claim 1, wherein the gypsum core fills at least 99 percent of the interstitial volume. ### Claim 16 (depends on 1) The method of claim 1, wherein the continuous barrier coating comprises a binder and at least one inorganic filler. ### Claim 17 (depends on 1) The method of claim 1, wherein the continuous barrier coating comprises a plurality of pin holes that provide for water vapor transmission across the coating. ### Claim 18 (depends on 1) The method of claim 1, wherein no surfactant is present in the continuous barrier coating. ### Claim 19 (depends on 1) The method of claim 1, wherein the gypsum panel has a Type X designation, when measured according to ASTM E119. ### Claim 20 (depends on 1) The method of claim 1, wherein the gypsum panel has a level 0 flame spread index and smoke develop index, when measured according to ASTM E84.