Gypsum panels, systems, and methods
AssigneeGeorgia-Pacific Gypsum LLC
InventorsVincent B. Thomas, Rochelle Bradford, Christopher J. Sanders, Yi-Hsien Harry Teng
Life of this patent
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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.
Claims24
A building sheathing system, comprising:
- at least two gypsum panels, each gypsum panel comprising:
- 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 of the gypsum core penetrates a remaining fibrous portion of the first fiberglass mat such that voids in the first fiberglass mat are substantially eliminated;
- and
- a seaming component configured to provide a seam at an interface between at least two of the gypsum panels,
- wherein the system provides a water-resistive air barrier in the absence of any externally-applied barrier product other than the seaming component, and
- wherein:
- the system passes a hydrostatic head test against water leakage, as measured by AATCC 127-2008, for a 22-inch head of water directly over the seaming component at the interface between the at least two gypsum panels, with no leaks after 5 hours,
- the system displays no water leaks when measured according to ICC Evaluation Service Acceptance Criteria 212,
- the system passes ICC Evaluation Service Acceptance Criteria 310, and/or
- the system displays no water leaks when measured according to ASTM E331 wall assembly test.
A building sheathing system, comprising:
- at least two gypsum panels, each gypsum panel comprising:
- 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 of the gypsum core penetrates a remaining fibrous portion of the first fiberglass mat such that voids in the first fiberglass mat are substantially eliminated;
- and
- a seaming component configured to provide a seam at an interface between at least two of the gypsum panels,
- wherein the system provides a water-resistive air barrier in the absence of any externally-applied barrier product other than the seaming component, and
- wherein the system has a water vapor permeance of at least 20 inch-pound units, as measured by ASTM E96 wet cup method.
A building sheathing system, comprising:
- at least two gypsum panels, each gypsum panel comprising:
- 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 of the gypsum core penetrates a remaining fibrous portion of the first fiberglass mat such that voids in the first fiberglass mat are substantially eliminated;
- and
- a seaming component configured to provide a seam at an interface between at least two of the gypsum panels,
- wherein the system provides a water-resistive air barrier in the absence of any externally-applied barrier product other than the seaming component, and
- wherein the system displays an air leakage rate of less than 0.04 cfm/ft2 at 1.57 lbs/ft2, when measured according to ASTM E2357.
Dependencies are inferred from the claim text.