Georgia-pacific Gypsum, Inc.

Stuart Brandon Gilley

Charles R Harrison

Lawrence Gollob

Clarence A Shelton

Xian-Yong Wang

Timothy R Fierbaugh

Yi-Hsien Harry Teng

Xianyong Wang

Hamed Mustafa Kayello

Bryan Wiltzius

Yongan Yuan

Gypsum panels and methods of making gypsum panels are provided. Methods of making gypsum panels include: depositing a first gypsum slurry onto a first surface of a first fiberglass mat; allowing the first gypsum slurry to set to form at least a portion of a gypsum core; and applying a substantially continuous barrier coating comprising a polymer binder to a second surface, opposite the first surface, of the first fiberglass mat, in an amount of from about 1 lb/MSF to about 40 lb/MSF, such that the substantially continuous barrier coating has an average thickness of from about 1 micron to about 100 microns, wherein the substantially continuous barrier coating eliminates at least 99 percent of pin holes present in the exposed second surface of the first fiberglass mat.

Gypsum panels, systems, and methods

Building panels, assemblies of building panels, and associated methods are provided. A building panel includes a structural core, such as a set gypsum core, at least one filamentous scrim associated with the core, and a nonwoven mat facer.

Building panels, assemblies, and associated methods

Gypsum panels and methods of making the same are provided. A method of making a gypsum panel includes forming a first gypsum slurry by combining stucco, water, a siliconate, and a phosphate salt or polymer, and setting the first gypsum slurry to form at least part of a core of the gypsum panel, wherein the gypsum panel displays a 2-hour water absorption test weight increase of at least 10 weight percent less than an otherwise identical comparative panel containing no phosphate salt or polymer in its core.

Gypsum panels and methods of making gypsum panels are provided. A method of making a gypsum panel includes combining gypsum stucco and a halide salt sequestration agent with water to form a gypsum slurry and setting the gypsum slurry to form at least a portion of a gypsum core, wherein the halide salt sequestration agent is present in an amount effective to sequester at least a portion of halide salt present in the gypsum stucco. A gypsum panel includes a gypsum core that comprises set gypsum and a halide salt sequestration agent, wherein the halide sequestration agent sequesters at least a portion of halide salt present in the gypsum core.

Gypsum panels, methods, and systems

Gypsum panels and methods of making the same are provided. A gypsum panel includes a gypsum core containing set gypsum and unexpanded perlite ore, wherein the unexpanded perlite ore is present in the gypsum core in an amount greater than any other component, other than the gypsum.

Gypsum panels, methods for their manufacture, and systems and methods for monitoring environmental conditions with such panels are provided herein. The panels include a gypsum core having a first surface and an opposed second surface, a first facer material associated with the first surface of the gypsum core, and an environmental sensor assembly associated with the gypsum panel and configured to detect an environmental condition of the gypsum panel and wirelessly communicate data on the environmental condition to a reader.

Building panels, systems, and methods

Construction panels and other materials, methods for their manufacture, and systems and methods for monitoring environmental conditions with such panels are provided herein. The panels include a core having a first surface and an opposed second surface, and an environmental sensor assembly associated with the panel and configured to detect an environmental condition of the panel and wirelessly communicate data on the environmental condition to a reader.

Construction panels, materials, systems, and methods

Construction panels and other materials, methods for their manufacture, and systems and methods for monitoring environmental conditions with such panels are provided herein. The panels include at least one environmental sensor assembly associated with a panel core and configured to detect an environmental condition of the panel comprising moisture, pressure, or both, and wirelessly communicate data on the environmental condition to a reader.

Growing community of inventors

Atlanta, GA, United States of America

Stuart Brandon Gilley