Gypsum panels, systems, and methods

Abstract

Gypsum panels and methods for their manufacture are provided herein. The gypsum panels include a gypsum core having a first surface and a second opposed surface and a first fiberglass mat associated with the first surface of the gypsum core, such that gypsum from the gypsum core penetrates at least a portion of the first fiberglass mat.

1 . A gypsum panel, comprising:
 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 at least a portion 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, and   wherein at least the portion of the gypsum core comprises a latex binder in an amount effective to increase water resistance of the gypsum panel.   
     
     
         2 . The gypsum panel of  claim 1 , wherein the gypsum panel passes a hydrostatic head test against water leakage, as measured by AATCC 127. 
     
     
         3 . The gypsum panel of  claim 1 , wherein at least the portion of the gypsum core comprises the latex binder in a range from 1 lb/1000 ft 2  to 30 lb/1000 ft 2 . 
     
     
         4 . The gypsum panel of  claim 1 , wherein at least the portion of the gypsum core comprises the latex binder in an amount of at least 1 lb/1000 ft 2 . 
     
     
         5 . The gypsum panel of  claim 1 , wherein at least the portion of the gypsum core comprises the latex binder in an amount of at least 6 lb/1000 ft 2 . 
     
     
         6 . The gypsum panel of  claim 1 , wherein the latex binder comprises a styrene butadiene latex. 
     
     
         7 . The gypsum panel of  claim 6 , wherein the styrene butadiene latex is a sulfonated styrene butadiene copolymer emulsion. 
     
     
         8 . The gypsum panel of  claim 1 , wherein the latex binder is embedded within the continuous barrier coating. 
     
     
         9 . The gypsum panel of  claim 1 , wherein the gypsum panel exhibits a moisture weight gain of less than 0.5% at 22 inches of water over 5 hours, when measured according to an AATCC 127 test assembly. 
     
     
         10 . The gypsum panel of  claim 1 , wherein the gypsum panel exhibits a moisture weight gain of less than 0.7% at 5 inches of water over 24 hours in the presence of at least one fastener driven through the gypsum panel, when measured according to an ASTM D1970 test assembly. 
     
     
         11 . The gypsum panel of  claim 1 , wherein the gypsum panel exhibits a moisture weight gain of less than 25 g at 5 inches of water over 24 hours, when measured according to the AATCC 127 test assembly. 
     
     
         12 . The gypsum panel of  claim 1 , wherein the gypsum panel exhibits a moisture weight gain of less than 30 g at 5 inches of water over 48 hours, when measured according to the AATCC 127 test assembly. 
     
     
         13 . The gypsum panel of  claim 1 , wherein the gypsum panel exhibits a moisture weight gain of less than 1% at 5 inches of water over 48 hours in the presence of at least one fastener driven through the gypsum panel, when measured according to the ASTM D1970 test assembly. 
     
     
         14 . The gypsum panel of  claim 1 , wherein the continuous barrier coating comprises a gypsum slurry. 
     
     
         15 . The gypsum panel of  claim 14 , wherein the gypsum slurry has a wet density of a wet density of at least about 88 pcf. 
     
     
         16 . The gypsum panel of  claim 14 , wherein the gypsum slurry comprises a microwax emulsion. 
     
     
         17 . The gypsum panel of  claim 1 , wherein the continuous barrier coating is from about 5 percent to about 20 percent, by weight, of the gypsum core. 
     
     
         18 . The gypsum panel of  claim 1 , wherein the gypsum core has a multilayer structure.