Coated fibrous mat faced gypsum board resistant to water and humidity
AssigneeGeorgia-Pacific Corporation
InventorsGeorge W. Green, Brian G. Randall
Life of this patent
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Abstract
A fibrous mat-faced gypsum board is coated with a water-resistant resinous coating.
Claims29
A water-resistant structural panel comprising
- a gypsum core;
- a porous mat comprising mineral fibers facing at least one surface of said core;
- a substantially humidity- and water-resistant resinous coating containing a latex of resin solids mixed with water, said coating covering said mat to the extent that substantially none of said mineral fibers protrude from said coating,
- wherein said faced and coated surface of said core has a Modified Cobb Test surface water absorption value of no greater than about 0-2.4 grams, said coating capable of bonding with Portland cement-based mortar.
A water-resistant structural panel comprising
- a gypsum board consisting essentially of a set gypsum core sandwiched between and faced with glass fiber mats, the surface of one of said mats being coated with a latex resinous coating, said coating containing at least about 15 wt. % resin solids, filler, and water,
- said coating upon drying and setting being substantially non-water-absorbing when exposed to water and humidity and disposed in an amount when dry equivalent to at least about 50 lbs./1000 sq. ft. of board and covering said mat to the extent that substantially none of the fibers of said mat protrude from said coating,
- and the core of said board including therein a water-resistant additive in an amount sufficient to improve the water-resistant properties of said core,
- the coating when dry capable of bonding with aqueous Portland cement-based mortar and having a Modified Cobb Test surface water absorption value of no greater than about 0-2.4 grams, the coated board having a weight equivalent to no greater than about 2500 lbs./1000 sq. ft. when 1/2" thick.
A tile backer substrate capable of bonding with Portland cement-based mortar and comprising a fibrous glass mat-faced gypsum board coated with a substantially humidity- and water-resistant resinous latex coating containing at least about 15 wt. % resin solids prior to drying, said coating covering said mat to the extent that substantially none of the fibers of said mat protrude from said coating, said substrate having a Modified Cobb Test value of about 0-2.4 grams.
A water-resistant structural panel capable of bonding with Portland cement-based mortar and comprising a fibrous mat-faced gypsum board coated with a resinous latex coating containing resin solids and water, said coating upon setting and drying being substantially non-water-absorbing when exposed to water and humidity, said coating covering said mat to the extent that substantially none of the fibers of said mat protrude from said coating, said substrate being substantially free of pin holes capable of penetration by moisture and having a Modified Cobb Test value of about 0-2.4 grams.
Dependencies are inferred from the claim text.