COATINGS FOR GLASS REINFORCED FACED GYPSUM BOARD
First Claim
1. A method of finishing a gypsum board, the gypsum board having a surface gypsum layer in which a polymer additive has been entrained, comprising:
- a) forming a gypsum board including the polymer additive entrained in at least one surface layer;
b) applying a primary coating to the polymer entrained surface layer;
c) curing and drying the coated gypsum board;
d) passing the coated gypsum board through a direct roll coater wherein a second coating is deposited over the at least one surface layer of the gypsum board in which the polymer additive has been entrained and the primary coating has been applied;
wherein the second coating is preselected from materials capable of providing improved water resistance, increased surface tension and a rougher surface topology.
1 Assignment
0 Petitions
Accused Products
Abstract
A coating method for gypsum board having a surface gypsum layer in which a polymer additive has been entrained including forming a gypsum board including the polymer additive entrained in a surface layer, application of a preferably acrylic primary coating, curing and drying the gypsum board, passing the gypsum board through a first roll coater wherein a second fluid coating is deposited over the primary layer of the dried, coated gypsum board in which the polymer additive has been entrained, the coating then being dried and cured, wherein the coating material of the primary coating forms a chemical bond with the polymer additive entrained in the surface layer of the gypsum board and the polymer of the primary coating forms a chemical bond with the second fluid coating. A coating material which can form copolymer bonds with the second coating is then deposited on the second coating and then dried and cured, resulting in coated gypsum board having a low surface tension surface that is essentially impermeable to water and vapor or moisture penetration.
89 Citations
25 Claims
-
1. A method of finishing a gypsum board, the gypsum board having a surface gypsum layer in which a polymer additive has been entrained, comprising:
-
a) forming a gypsum board including the polymer additive entrained in at least one surface layer; b) applying a primary coating to the polymer entrained surface layer; c) curing and drying the coated gypsum board; d) passing the coated gypsum board through a direct roll coater wherein a second coating is deposited over the at least one surface layer of the gypsum board in which the polymer additive has been entrained and the primary coating has been applied; wherein the second coating is preselected from materials capable of providing improved water resistance, increased surface tension and a rougher surface topology. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
-
- 21. A coated gypsum board, the gypsum board having a surface layer in which a polymer additive has been entrained, further comprising a primary coating that includes a chemical bond between the polymer additive entrained in the surface layer of the gypsum board and the coating material which is preselected so as to produce an increased surface tension thereby providing a raised surface having isotropic texture area directional features, whereby the surface contact area of the board is increased to provide an increased chemical and mechanical adhesive surface capable of attaching tiles.
Specification