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 . A gypsum board comprising:
a gypsum core, the gypsum core comprising calcium sulfate dihydrate in an amount of at least 50 wt. % of the gypsum core; and
a glass mat facing material including a first coating and a second coating, wherein the first coating is continuous, the first coating comprising a resin including an acrylic resin, a siloxane rubber, or a mixture thereof and a hydrophobic additive comprising an organosilane, wherein the second coating is a non-continuous coating;
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;
wherein the gypsum board has a density from about 20 pcf to about 60 pcf.
2 . The gypsum board of claim 1 , wherein the gypsum board passes at least two of the three air and water barrier tests specified in AC-212.
3 . The gypsum board of claim 1 , wherein the gypsum board passes all three of the air and water barrier tests specified in AC-212.
4 . The gypsum board of claim 1 , 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.
5 . The gypsum board of claim 1 , 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.
6 . The gypsum board of claim 1 , wherein the resin is present in the first coating in an amount of 20 wt. % to 98 wt. % and/or the hydrophobic additive is present in the first coating in an amount of 0.001 wt. % to 25 wt. %.
7 . The gypsum board of claim 1 , wherein the resin comprises an acrylic resin.
8 . The gypsum board of claim 7 , wherein the acrylic resin comprises an acrylate monomer or polymer.
9 . The gypsum board of claim 7 , wherein the acrylic resin comprises a methacrylate monomer or polymer.
10 . The gypsum board of claim 1 , wherein the resin comprises a siloxane rubber.
11 . The gypsum board of claim 10 , wherein the siloxane rubber comprises a polyorganosiloxane.
12 . The gypsum board of claim 10 , wherein the siloxane rubber comprises a polydimethylsiloxane.
13 . The gypsum board of claim 1 , wherein the organosilane comprises one or more components having the following general structure:
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.
14 . The gypsum board of claim 13 , wherein X is a non-hydrolysable organic moiety comprising an epoxy moiety.
15 . The gypsum board of claim 13 , wherein X is a non-hydrolysable organic moiety comprising an amino moiety.
16 . The gypsum board of claim 13 , wherein R is an alkylene.
17 . The gypsum board of claim 1 , wherein the second coating is in the form of a pattern.
18 . The gypsum board of claim 1 , wherein the second coating is at least ⅛ inch thick.
19 . The gypsum board of claim 1 , wherein the resin is present in the first coating in an amount of 20 wt. % to 98 wt. % and the hydrophobic additive is present in the first coating in an amount of 0.001 wt. % to 25 wt. %.
20 . A gypsum board comprising:
a gypsum core, the gypsum core comprising calcium sulfate dihydrate in an amount of at least 50 wt. % of the gypsum core; and
a glass mat facing material including a first coating and a second coating, wherein the first coating comprises a resin including an acrylic resin, a siloxane rubber, or a mixture thereof and a hydrophobic additive comprising an organosilane, wherein the second coating is a non-continuous coating, the second coating being at least ⅛ inch thick;
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;
wherein the gypsum board has a density from about 20 pcf to about 60 pcf.
21 . The gypsum board of claim 20 , wherein the resin is present in the first coating in an amount of 20 wt. % to 98 wt. % and/or the hydrophobic additive is present in the first coating in an amount of 0.001 wt. % to 25 wt. %.
22 . The gypsum board of claim 20 , wherein the resin is present in the first coating in an amount of 20 wt. % to 98 wt. % and the hydrophobic additive is present in the first coating in an amount of 0.001 wt. % to 25 wt. %.
23 . The gypsum board of claim 22 , wherein the second coating is in the form of a pattern.