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 g
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.
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1. A method of constructing a building sheathing system, comprising: installing at least two gypsum panels having an interface therebetween to form an external building sheathing; andapplying a seaming component at the interface between the at least two gypsum panels,wherein, in the absence of any e
1. A method of constructing a building sheathing system, comprising: installing at least two gypsum panels having an interface therebetween to form an external building sheathing; andapplying a seaming component at the interface between the at least two gypsum panels,wherein, in the absence of any externally applied barrier product, other than the seaming component: the system passes a hydrostatic head test against water leakage, as measured by AATCC 127-2008,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/orthe system displays no water leaks when measured according to ASTM E331 wall assembly test,wherein the at least two gypsum panels each comprise a gypsum core associated with a first fiberglass mat having a continuous barrier coating that comprises a plurality of pin holes that provide for water vapor transmission across the 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, andwherein the gypsum core of each gypsum panel comprises a first gypsum layer that at least partially penetrates the remaining fibrous portion of the first fiberglass mat, the first gypsum layer being formed by a gypsum slurry that comprises a wetting agent in an amount effective to bring a slurry surface tension of the first gypsum layer from about 30 dyne/cm to about 55 dyne/cm. 2. The method of claim 1, wherein the gypsum core of each gypsum panel comprises a first gypsum layer that at least partially penetrates the remaining fibrous portion of the first fiberglass mat, the first gypsum layer having a slurry density of about 88 pcf to about 98 pcf. 3. The method of claim 1, wherein the first gypsum layer is present in an amount from about 5 percent to about 20 percent, by weight, of the gypsum core. 4. The method of claim 1, wherein the seaming component comprises tape or a bonding material. 5. The method of claim 4, wherein the seaming component comprises a bonding material selected from the group consisting of synthetic stucco plasters, cement plasters, synthetic acrylics, sand-filled acrylics, solvent-based acrylics, solvent-based butyls, polysulfides, polyurethanes, silicones, silyl-modified polymers, water-based latexes, EVA latexes, and acrylic latexes. 6. The method of claim 1, wherein the system passes AATCC hydrostatic head test method 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. 7. The method of claim 1, wherein the system has a water vapor permeance of at least 20 inch-pound units, as measured by ASTM E96 wet cup method. 8. The method of claim 1, 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. 9. The method of claim 1, wherein the system is substantially free of any externally-applied fabric membrane, liquid coating, or self-adhered membrane. 10. A method of constructing a building sheathing system, comprising: installing at least two gypsum panels having an interface therebetween to form an external building sheathing, each gypsum panel comprising a gypsum core associated with a first fiberglass mat having a continuous barrier coating that comprises a plurality of pin holes that provide for water vapor transmission across the 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; andapplying a seaming component at the interface between the at least two gypsum panels,wherein the system is substantially free of any externally-applied fabric membrane, liquid coating, or self-adhered membrane, andwherein the gypsum core of each gypsum panel comprises a first gypsum layer that at least partially penetrates the remaining fibrous portion of the first fiberglass mat, the first gypsum layer being formed by a gypsum slurry that comprises a wetting agent in an amount effective to bring a slurry surface tension of the first gypsum layer from about 30 dyne/cm to about 55 dyne/cm. 11. The method of claim 10, wherein the gypsum core of each gypsum panel comprises a first gypsum layer that at least partially penetrates the remaining fibrous portion of the first fiberglass mat, the first gypsum layer having a slurry density of about 88 pcf to about 98 pcf. 12. The method of claim 10, wherein the first gypsum layer is present in an amount from about 5 percent to about 20 percent, by weight, of the gypsum core. 13. The method of claim 10, wherein the seaming component comprises tape or a bonding material. 14. The method of claim 13, wherein the seaming component comprises a bonding material selected from the group consisting of synthetic stucco plasters, cement plasters, synthetic acrylics, sand-filled acrylics, solvent-based acrylics, solvent-based butyls, polysulfides, polyurethanes, silicones, silyl-modified polymers, water-based latexes, EVA latexes, and acrylic latexes. 15. The method of claim 10, wherein the system passes AATCC hydrostatic head test method 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. 16. The method of claim 10, wherein the system has a water vapor permeance of at least 20 inch-pound units, as measured by ASTM E96 wet cup method. 17. The method of claim 10, 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.
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이 특허에 인용된 특허 (6)
Green George W. (Stone Mountain GA) Randall Brian G. (Stone Mountain GA), Coated fibrous mat-faced gypsum board.
Tanis Rick A. ; Merser N. Keith ; Hyde-Smith Peter K., Method of filling a seam of a panel assembly using a thixotropic polyurethane elastomeric filler adhesive.
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