US4647496A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Use of fibrous mat-faced gypsum board in exterior finishing systems for buildings
Assignee: GP Gypsum Corp
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Filing: 1984-02-27
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Granted: 1987-03-03
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Expires: 2004-02-27
Abstract
Abstract An exterior finishing system for a building, including particularly an exterior insulation system, which includes a fibrous mat-faced gypsum board, preferably a board in which the set gypsum core thereof is water resistant, and preferably one in which the set gypsum core is sandwiched between two sheets of porous glass mat, with the outer surface of at least one of said mats being substantially free of set gypsum, and means for preparing the board, including control of the viscosity of the aqueous gypsum slurry from which the set gypsum core of the board is formed. Also, the use of fibrous mat-faced gypsum board as the shaft liner panel in a shaft wall assembly.
Inventors
- 👤 Charles W. Lehnert
- 👤 Brian G. Randall
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 22:42
CPC Classifications
B; B32; B32B; B32B13/00; B32B13/14; B28; B28B; B28B19/00; B28B19/0092; B28B23/00; B28B23/0006; B32B3/00; B32B3/26; B32B7/00; B32B7/04; B32B7/12; E; E04; E04C; E04C2/00; E04C2/02; E04C2/04; E04C2/043; E04C2/26; E04C2/284; E04C2/288; E04D; E04D11/00; E04D11/02; E04D13/00; E04D13/16; E04D13/1606; E04D13/1643; E04D13/1668; E04F; E04F13/00; E04F13/02; E04F13/04; E04F13/047; B32B2262/00; B32B2262/10; B32B2262/101; B32B2305/00; B32B2305/08; B32B2307/00; B32B2307/30; B32B2307/304; B32B2307/70; B32B2307/726; B32B2307/7265; B32B2607/00; Y; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249953; Y10T428/249967; Y10T428/249968; Y10T428/31504; Y10T428/31801; Y10T428/31815; Y10T442/00; Y10T442/60; Y10T442/659; Y10T442/665; Y10T442/696
Claims Analysis
Total Claims: 38
Claim 1
Independent Claim
69 words
An exterior insulation system for a building comprising a glass mat-faced gypsum support surface, insulating material having an inner surface and an outer surface, the inner surface of which is adhered to said support surface by an adhesive material, the insulating material being substantially free of channels penetrating therethrough and between said inner and outer surfaces, and an exterior finishing material overlying the outer surface of said insulating material.
Claim 2
Dependent Claim
69 words
An exterior insulation system for a building comprising a glass mat-faced gypsum support surface, insulating material having an inner surface and an outer surface, the inner surface of which is adhered to said support surface by an adhesive material, the insulating material being substantially free of channels penetrating therethrough and between said inner and outer surfaces, and an exterior finishing material overlying the outer surface of said insulating material.
Claim 3
Dependent Claim
55 words
A system in accordance with claim 1 wherein said support surface comprises a plurality of glass mat-faced gypsum core panels in abutting relationship, with panels of said insulating material in abutting relationship adhered to said panels comprising said support surface, and exterior finishing material having weathering and aesthetic characteristics overlying said panels of insulating material.
Claim 4
Dependent Claim
26 words
A system according to claim 1 or 2 wherein said mat is a glass fiber mat comprising randomly distributed glass filaments bonded by an adhesive material.
Claim 5
Dependent Claim
104 words
A system in accordance with claim 1 or 2 wherein said support surface comprises panels of gypsum board, said board comprising a set gypsum core sandwiched between two sheets of porous glass mat, each of which has an inner and outer surface and a predetermined thickness, said mat comprisng randomly distributed glass fibers bonded by an adhesive material, the inner surface of each of said mats adhered to said gypsum core by set gypsum of said core penetrating but part-way into the thickness of each of said mats, and wherein the outer surface of each of said mats is substantially free of set gypsum.
Claim 6
Dependent Claim
24 words
An exterior insulation system in accordance with claim 1 or 2 including a reinforcing member sandwiched between said insulating material and said finishing material.
Claim 7
Dependent Claim
117 words
A system in accordance with claim 1 or 2 wherein said support surface comprises panels of gypsum board, said board comprising a set gypsum core sandwiched between two sheets of porous glass mat, each of which has an inner and outer surface, said mat comprising randomly distributed glass fibers bonded by an adhesive material, the inner surface of each of said mats adhered to said gypsum core by a portion of the set gypsum comprising said core, the outer surface of one of said mats having portions thereof coated with set gypsum comprising portions of the set gypsum of said core, and the outer surface of the other of said mats being substantially free of set gypsum.
Claim 8
Dependent Claim
24 words
A system according to claim 6 wherein said insulating material is adhered to said mat having its outer surface substantially free of set gypsum.
Claim 9
Dependent Claim
46 words
A system in accordance with claim 6 wherein said gypsum-coated mat is substantially penetrated by set gypsum over substantial area portions of the outer surface thereof, and wherein the set gypsum of the core penetrates but part-way into the thickness of the other of said mats.
Claim 10
Dependent Claim
28 words
A system in accordance with claim 8 wherein about 45 to about 55% of the outer surface of said gypsum-coated mat is substantially penetrated by the set gypsum.
Claim 11
Dependent Claim
26 words
A system according to claim 8 or 9 wherein said insulating material is adhered to said mat having its outer surface substantially free of set gypsum.
Claim 12
Dependent Claim
74 words
An exterior finishing system for a building comprising an underlying structural support element which is covered with an overlying finishing material, said support element including gypsum board comprising a set gypsum core sandwiched between two sheets of porous glass fiber mat, the gypsum core including one or more additives which are effective in improving the water-resistant properties of the board in an amount at least sufficient to impart to the board improved water-resistant properties.
Claim 13
Dependent Claim
74 words
An exterior finishing system for a building comprising an underlying structural support element which is covered with an overlying finishing material, said support element including gypsum board comprising a set gypsum core sandwiched between two sheets of porous glass fiber mat, the gypsum core including one or more additives which are effective in improving the water-resistant properties of the board in an amount at least sufficient to impart to the board improved water-resistant properties.
Claim 14
Dependent Claim
29 words
A system in accordance with claim 11 wherein said core absorbs less than 5% water when tested in accordance with ASTM method C-473 with only the edges thereof exposed.
Claim 15
Dependent Claim
26 words
A system in accordance with claim 11 wherein said core is prepared from a calcined gypsum composition containing at least about 3 wt. % wax-asphalt emulsion.
Claim 16
Dependent Claim
26 words
A system according to claim 13 wherein the amount of said emulsion is within the range of about 3 wt. % to about 10 wt. %.
Claim 17
Dependent Claim
26 words
A system according to claim 14 wherein the amount of said emulsion is within the range of about 5 wt. % to about 7 wt. %.
Claim 18
Dependent Claim
21 words
A system in accordance with claim 13 wherein said core is prepared from a calcined gypsum composition including also poly(vinyl alcohol).
Claim 19
Dependent Claim
32 words
A system according to claim 16 wherein the amounts of said poly(vinyl alcohol) and said wax-asphalt emulsion are at least about 0.05 wt. % and at least about 2 wt. % respectively.
Claim 20
Dependent Claim
30 words
A system according to claim 17 wherein said amounts are about 0.15 wt. % to about 0.4 wt. % and about 3.0 wt. % to about 5.0 wt. % respectively.
Claim 21
Dependent Claim
112 words
An exterior insulation system for a building having a support surface including gypsum board comprising a set gypsum core faced with a glass mat, the gypsum core including one or more additives which are effective in improving the water-resistant properties of the board in an amount at least sufficient to impart to the board improved water-resistant properties, insulating material having an inner surface and an outer surface, the inner surface of which is adhered to said glass mat by an adhesive material, the insulating material being substantially free of channels penetrating therethrough and between said inner and outer surfaces, and an exterior finishing material overlying the outer surface of said insulating material.
Claim 22
Dependent Claim
112 words
An exterior insulation system for a building having a support surface including gypsum board comprising a set gypsum core faced with a glass mat, the gypsum core including one or more additives which are effective in improving the water-resistant properties of the board in an amount at least sufficient to impart to the board improved water-resistant properties, insulating material having an inner surface and an outer surface, the inner surface of which is adhered to said glass mat by an adhesive material, the insulating material being substantially free of channels penetrating therethrough and between said inner and outer surfaces, and an exterior finishing material overlying the outer surface of said insulating material.
Claim 23
Dependent Claim
31 words
A system according to claim 19 wherein the core of said board absorbs less than 5% water when tested in accordance with ASTM method C-473 with only the edges thereof exposed.
Claim 24
Dependent Claim
42 words
A system according to claim 19 wherein the core of said board is sandwiched between two sheets of porous glass fiber mat and absorbs less than 5% water when tested in accordance with ASTM method, C-473 with only the edges thereof exposed.
Claim 25
Dependent Claim
39 words
A system according to claim 19 wherein the core of said board is sandwiched between two sheets of porous glass fiber mat and is prepared from a calcined gypsum composition containing at least about 3 wt. % wax-asphalt emulsion.
Claim 26
Dependent Claim
20 words
A system according to claim 22 wherein said core is prepared from a calcined gypsum composition including also poly(vinyl alcohol).
Claim 27
Dependent Claim
26 words
A system according to claim 22 wherein the amount of said emulsion is within the range of about 3 wt % to about 10 wt. %.
Claim 28
Dependent Claim
26 words
A system according to claim 24 wherein the amount of said emulsion is within the range of about 5 wt. % to about 7 wt. %.
Claim 29
Dependent Claim
32 words
A system according to claim 23 wherein the amounts of said poly(vinyl alcohol) and said wax-asphalt emulsion are at least about 0.05 wt. % and at least about 2 wt. % respectively.
Claim 30
Dependent Claim
30 words
A system according to claim 26 wherein said amounts are about 0.05 wt. % to about 0.4 wt. % and about 3.0 wt. % to about 5.0 wt. % respectively.
Claim 31
Dependent Claim
57 words
A system in accordance with claim 19, 22, 23, 20, 21, 24, 25, 26, or 27 including a plurality of said boards in abutting relationship and panels of said insulating material in abutting relationship adhered to said glass mat, and wherein said exterior finishing material has weathering and aesthetic characteristics and overlies said panels of insulating material.
Claim 32
Dependent Claim
105 words
A system in accordance with claim 28 wherein said set gypsum core is sandwiched between two sheets of porous glass mat, each of which has an inner and outer surface, said mat comprising randomly distributed glass fibers bonded by an adhesive material, the inner surface of each of said mats adhered to said gypsum core by a portion of the set gypsum comprising said core, the outer surface of one of said mats having portions thereof coated with set gypsum comprising portions of the set gypsum of said core, and the outer surface of the other of said mats being substantially free of set gypsum.
Claim 33
Dependent Claim
25 words
A system in accordance with claim 29 wherein said mat is a glass fiber mat comprising randomly distributed glass filaments bonded by an adhesive material.
Claim 34
Dependent Claim
25 words
A system in accordance with claim 29 wherein said insulating material is adhered to said mat having its outer surface substantially free of set gypsum.
Claim 35
Dependent Claim
46 words
A system in accordance with claim 29 wherein said gypsum-coated mat is substantially penetrated by set gypsum over substantial area portions of the outer surface thereof, and wherein the set gypsum of the core penetrates but part-way into the thickness of the other of said mats.
Claim 36
Dependent Claim
28 words
A system in accordance with claim 32 wherein about 45 to about 55% of the outer surface of said gypsum-coated mat is substantially penetrated by the set gypsum.
Claim 37
Dependent Claim
25 words
A system in accordance with claim 32 wherein said insulating material is adhered to said mat having its outer surface substantially free of set gypsum.
Claim 38
Dependent Claim
27 words
A system according to claim 11, 12, 13, 14, 15, 16, 17, or 18 wherein said mat comprises randomly distributed glass filaments bonded by an adhesive material.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1990-03-02 | 1990-09-01 | 1991-03-03 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1994-03-02 | 1994-09-01 | 1995-03-03 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-03-02 | 1998-09-01 | 1999-03-03 | $7700.00 | Window Closed / Lapsed |