IP Library › Granted Patent US 12,734,724
Granted Patent B2
US 12,734,724 · App. 15/996,983 · Granted Sep 15, 2026

Air and water barrier building panels

Inventors: Brian G. Randall (Charlotte, NC); Joseph J. Bailey (Charlotte, NC); Eli Stav (Charlotte, NC); Brian Bland (Charlotte, NC); Gene Whittington (Indian Land, SC); R. G. Iyer (Fort Mill, SC)
Assignee: Gold Bond Building Products, LLC
B27N3/06B27N3/04B32B13/00C03C25/1025C04B11/036C04B28/14C04B28/145D21F13/00E04C2/06C04B2111/00267C04B2111/00275C04B2111/00293C04B2111/00405C04B2111/00482C04B2111/0062C04B2111/27
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Quick Facts
Patent No.
US 12,734,724
App. No.
15/996,983
Granted
Sep 15, 2026
Kind
B2
Abstract

A method for improving the air and/or water barrier performance of a building panel is disclosed. The building panel may be a gypsum board or cement board. In particular, the board may have improved resistance to bulk water penetration or permeation while maintaining breathability with respect to water vapor.

Claims (32)

1 . A method of making a gypsum panel having improved air and water barrier performance, the method comprising:

providing a first nonwoven facing material,

providing a board slurry on the first nonwoven facing material, the board slurry comprising a binder, the binder comprising a starch, the board slurry penetrating the first nonwoven facing material, the board slurry forming a board core, the board core being free of polyvinyl alcohol,

providing a second facing material on the board slurry, and

applying a hydrophobic material to the first nonwoven facing material prior to providing the first nonwoven facing material, wherein the hydrophobic material is applied on a side of the first nonwoven facing material opposite a side adjacent the board slurry and forms a coating thereon, wherein the hydrophobic material penetrates the first nonwoven facing material, wherein the hydrophobic material is present in an amount of about 0.01 wt. % to about 10.0 wt. % based on the weight of the first nonwoven facing material and wherein the coating consists essentially of a polysiloxane comprising methylhydrogen polysiloxane or a polydialkylsiloxane,

wherein the total amount of lignosulfonates in the board slurry is 0.1 wt. % or less.

2 . The method of claim 1 , wherein the hydrophobic material is further applied to the second facing material after being placed on the board slurry wherein the hydrophobic material is applied on a side of the second facing material opposite a side adjacent the board slurry.

3 . The method of claim 1 , wherein the hydrophobic material is further provided in the board slurry which then migrates to the first nonwoven facing material, the second facing material, or both.

4 . The method of claim 1 , wherein the hydrophobic material comprises methylhydrogen polysiloxane.

5 . The method of claim 1 , wherein the hydrophobic material comprises a polydialkylsiloxane.

6 . The method of claim 1 , wherein the hydrophobic material comprises polydimethylsiloxane.

7 . The method of claim 1 , wherein the first nonwoven facing material, the second facing material, or both have hydrophobic properties and further wherein a hydrophilic facing material is positioned between the first nonwoven facing material, the second facing material, or both and the board slurry.

8 . The method of claim 1 , wherein the first nonwoven facing material is a fiberglass mat facing material.

9 . The method of claim 1 , wherein the second facing material is a nonwoven facing material.

10 . The method of claim 1 , wherein the hydrophobic material is further provided in the board slurry which then migrates to the first nonwoven facing material, the second facing material, or both, wherein the hydrophobic material densifies the gypsum of the board slurry such that the board slurry has an increased density at the interface between the first nonwoven facing material and the board slurry, the density at the interface between the first nonwoven facing material and the board slurry being higher than the density of the center of the board slurry.

11 . The method of claim 1 , wherein the coating is the only coating present on the side of the first nonwoven facing material opposite the side adjacent the board slurry.

12 . The method of claim 1 , wherein the coating consists of the polysiloxane comprising methylhydrogen polysiloxane or the polydialkylsiloxane.

13 . A method of making a gypsum panel having improved air and water barrier performance, the method comprising:

providing a first nonwoven facing material,

providing a board slurry on the first nonwoven facing material, the board slurry forming a board core, the board core being free of polyvinyl alcohol, and

providing a second facing material on the board slurry,

wherein a hydrophobic material is applied to the first nonwoven facing material and forms a coating thereon, wherein the hydrophobic material is applied on a side of the first nonwoven facing material opposite a side adjacent the board slurry, wherein the hydrophobic material penetrates the first nonwoven facing material, wherein the hydrophobic material is present in an amount of about 0.01 wt. % to about 10.0 wt. % based on the weight of the first nonwoven facing material and wherein the coating consists essentially of a polysiloxane comprising methylhydrogen polysiloxane or a polydialkylsiloxane, wherein a polymeric coating is not applied on the side of the first nonwoven facing material adjacent the board slurry,

wherein the application of the hydrophobic material to the first nonwoven facing material forms a hydrophobic facing material, wherein fly ash is not applied to form the hydrophobic facing material,

wherein the total amount of lignosulfonates in the board slurry is 0.1 wt. % or less.

14 . The method of claim 13 , wherein the coating consists of the polysiloxane comprising methylhydrogen polysiloxane or the polydialkylsiloxane.

15 . The method of claim 13 , wherein the hydrophobic material is further provided in the board slurry which then migrates to the first nonwoven facing material, the second facing material, or both.

16 . The method of claim 13 , wherein the hydrophobic material comprises methylhydrogen polysiloxane.

17 . The method of claim 13 , wherein the hydrophobic material comprises a polydialkylsiloxane.

18 . The method of claim 13 , wherein the hydrophobic material comprises polydimethylsiloxane.

19 . The method of claim 13 , wherein the first nonwoven facing material, the second facing material, or both have hydrophobic properties and further wherein a hydrophilic facing material is positioned between the first nonwoven facing material, the second facing material, or both and the board slurry.

20 . The method of claim 13 , wherein the first nonwoven facing material is a fiberglass mat facing material.

21 . The method of claim 13 , wherein the hydrophobic material is further provided in the board slurry which then migrates to the first nonwoven facing material, the second facing material, or both, wherein the hydrophobic material densifies the gypsum of the board slurry such that the board slurry has an increased density at the interface between the first nonwoven facing material and the board slurry, the density at the interface between the first nonwoven facing material and the board slurry being higher than the density of the center of the board slurry.

Assignments (4)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 12, 2021
From: NATIONAL GYPSUM PROPERTIES, LLC
To: PROFORM FINISHING PRODUCTS, LLC
Reel/Frame 056214/0237 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 12, 2021
From: PROFORM FINISHING PRODUCTS, LLC
To: GOLD BOND BUILDING PRODUCTS, LLC
Reel/Frame 056215/0931 →
SECURITY INTEREST Recorded Nov 25, 2020
From: NATIONAL GYPSUM PROPERTIES, LLC
To: BANK OF AMERICA, N.A., AS COLLATERAL AGENT
Reel/Frame 054468/0084 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 28, 2018
From: RANDALL, BRIAN G.; BAILEY, JOSEPH J.; STAV, ELI; BLAND, BRIAN; WHITTINGTON, GENE; IYER, R.G.
To: NATIONAL GYPSUM PROPERTIES, LLC
Reel/Frame 046225/0794 →
Continuity (2)
Provisional Application 62514506 · Jun 2, 2017
Related Publication 20180345532A1 · Dec 6, 2018
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