GYPSUM BOARD INCLUDING A COATED FACING MATERIAL
In general, the present invention is directed to a gypsum board comprising a gypsum core and a glass mat facing material including a coating. The coating comprises a resin including an acrylic resin, a siloxane rubber, or a mixture thereof and hydrophobic additive comprising an organosilane. The gypsum board passes at least one of the three air and water barrier tests specified in AC-212 wherein the tests comprise a water penetration barrier test as conducted in accordance with ASTM E331-00, a hydrostatic head test as conducted in accordance with AATCC 127-2008, or an air barrier test as conducted in accordance with ASTM E2357-11.
1 - 27 . (canceled)
28 . A gypsum board comprising:
a gypsum core and a glass mat facing material including a coating, wherein the coating comprises a resin including an acrylic resin, a siloxane rubber, or a mixture thereof and a hydrophobic additive comprising an organosilane;
wherein the gypsum board passes at least one of the three air and water barrier tests specified in AC-212 wherein the tests comprise a water penetration barrier test as conducted in accordance with ASTM E331-00, a hydrostatic head test as conducted in accordance with AATCC 127-2008, or an air barrier test as conducted in accordance with ASTM E2357-11.
29 . The gypsum board of claim 28 , wherein the gypsum board passes at least two of the three air and water barrier tests specified in AC-212.
30 . The gypsum board of claim 28 , wherein the gypsum board passes all three of the air and water barrier tests specified in AC-212.
31 . The gypsum board of claim 28 , wherein the gypsum board exhibits a passing rate of at least 80% as determined in accordance with the hydrostatic head test of AATCC 127-2008.
32 . The gypsum board of claim 28 , wherein the gypsum board further exhibits a passing rate of at least 80% for a nail sealability test determined in accordance with ASTM D1970-20, section 7.9.
33 . The gypsum board of claim 28 , wherein the resin is present in the coating in an amount of 20 wt. % or more to 98 wt. % or less and/or the hydrophobic additive is present in the coating in amount of 0.001 wt. % or more to 25 wt. % or less.
34 . The gypsum board of claim 28 , wherein the resin comprises an acrylic resin.
35 . The gypsum board of claim 28 , wherein the acrylic resin comprises an acrylate monomer or polymer.
36 . The gypsum board of claim 28 , wherein the acrylic resin comprises a methacrylate monomer or polymer.
37 . The gypsum board of claim 28 , wherein the resin comprises a siloxane rubber.
38 . The gypsum board of claim 28 , wherein the siloxane rubber comprises a polyorganosiloxane.
39 . The gypsum board of claim 28 , wherein the siloxane rubber comprises a polydimethylsiloxane.
40 . The gypsum board of claim 28 , wherein the organosilane comprises one or more components having the following general structure:
X—R—Si(OR′) 3
wherein
X can be a non-hydrolysable organic moiety comprising an epoxy, amino, vinyl methacryloxy, or sulfido moiety;
R can be an arylene or an alkylene; and
OR′ can be a moiety that can be hydrolysable.
41 . The gypsum board of claim 40 , wherein X is a non-hydrolysable organic moiety comprising an epoxy moiety.
42 . The gypsum board of claim 40 , wherein X is a non-hydrolysable organic moiety comprising an amino moiety.
43 . The gypsum board of claim 40 , wherein R is an alkylene.
44 . The gypsum board of claim 28 , wherein the coating is a monolayer coating.
45 . The gypsum board of claim 28 , wherein the coating is a multilayer coating.
46 . The gypsum board of claim 45 , wherein the coating comprises a second coating.
47 . The gypsum board of claim 46 , wherein the second coating is a non-continuous coating.
48 . The gypsum board of claim 46 , wherein the second coating is in the form of a pattern.