Cementitious Panels with Swellable Materials and Methods of Providing a Moisture or Water Barrier in Cementitious Panels Using Swellable Materials
Provided are cementitious panel that include a swellable material within a core layer, a dense layer, and/or a sheet of facing material that make up a cementitious panel, as well as methods of manufacturing such cementitious panels that include a swellable material and methods of providing a moisture or water barrier in a cementitious panel.
1 . A gypsum panel, comprising:
a core layer comprising gypsum; and
a plurality of sheets of facing material surrounding the core layer, the plurality of sheets of facing material comprising a first sheet of facing material and a second sheet of facing material sandwiching the core layer, the first sheet of facing material, the second sheet of facing material, or both having a coating applied to the inner surface thereof, the coating comprising a polymer, the polymer being present in the coating in an amount of at least 0.1% by weight of the coating.
2 . The gypsum panel of claim 1 , wherein the polymer comprises a polyacrylamide.
3 . The gypsum panel of claim 1 , wherein the polymer comprises a polyvinyl alcohol.
4 . The gypsum panel of claim 1 , wherein the polymer is present in the coating in an amount of at least 50% by weight of the coating.
5 . The gypsum panel of claim 1 , wherein the polymer is present in the coating in an amount of at least 70% by weight of the coating.
6 . The gypsum panel of claim 1 , wherein the polymer forms a film.
7 . The gypsum panel of claim 6 , wherein the film is a porous film.
8 . The gypsum panel of claim 1 , wherein the polymer comprises particles and/or discrete domains of a micro-scale size, the particles and/or discrete domains having an average cross-sectional dimension from 1 μm to 2000 μm.
9 . The gypsum panel of claim 1 , wherein the polymer comprises particles and/or discrete domains of a nano-scale size, the particles and/or discrete domains having an average cross-sectional dimension from 1 nm to 1,000 nm.
10 . The gypsum panel of claim 1 , wherein the coating comprises a binder, the binder comprising a polyvinyl acetate.
11 . A gypsum panel, comprising:
a core layer comprising gypsum; and
a plurality of sheets of facing material surrounding the core layer, the plurality of sheets of facing material comprising a first sheet of facing material and a second sheet of facing material sandwiching the core layer, the first sheet of facing material, the second sheet of facing material, or both having a coating applied to the inner surface thereof, the coating comprising a swellable material, the swellable material being a polymer, the swellable material being present in the coating in an amount of at least 0.1% by weight of the coating.
12 . The gypsum panel of claim 11 , wherein the swellable material comprises a polyacrylamide.
13 . The gypsum panel of claim 11 , wherein the swellable material comprises a polyvinyl alcohol.
14 . The gypsum panel of claim 11 , wherein the swellable material is present in the coating in an amount of at least 50% by weight of the coating.
15 . The gypsum panel of claim 11 , wherein the swellable material is present in the coating in an amount of at least 70% by weight of the coating.
16 . The gypsum panel of claim 11 , wherein the swellable material forms a film.
17 . The gypsum panel of claim 16 , wherein the film is a porous film.
18 . The gypsum panel of claim 11 , wherein the swellable material comprises particles and/or discrete domains of a micro-scale size, the particles and/or discrete domains having an average cross-sectional dimension from 1 μm to 2000 μm.
19 . The gypsum panel of claim 11 , wherein the swellable material comprises particles and/or discrete domains of a nano-scale size, the particles and/or discrete domains having an average cross-sectional dimension from 1 nm to 1,000 nm.
20 . The gypsum panel of claim 11 , wherein the coating comprises a binder, the binder comprising a polyvinyl acetate.