Coated gypsum board products and method of manufacture

Abstract

A method of producing a coated gypsum board includes depositing a gypsum slurry to form a wet gypsum board having a gypsum core; applying a coating to the wet gypsum board; and drying the wet gypsum board, wherein the step of applying the coating occurs prior to the step of drying and the coating penetrates through at least a portion of the facing sheet and into at least a portion of the gypsum core. A board produced by the method is made with a coating that matches a joint compound.

What is claimed is:  
     
         1 . A gypsum board having a coating applied thereon, the gypsum board comprising: 
 a gypsum core having a first side and a second side and a facing sheet disposed on the first side; and    a coating disposed on at least a portion of the facing sheet,    wherein at least a portion of the coating penetrates through at least a portion of the facing sheet and into the gypsum core.    
     
     
         2 . The gypsum board of  claim 1 , wherein the coating penetrates into the gypsum core to a substantially uniform depth across an area of the gypsum board.  
     
     
         3 . The gypsum board of  claim 1 , wherein a thickness of the coating is up to 30 mils.  
     
     
         4 . The gypsum board of  claim 3 , wherein the thickness of the coating is preferably 3-20 mils.  
     
     
         5 . The gypsum board of  claim 1 , wherein the coating is a joint compound.  
     
     
         6 . The gypsum board of  claim 1 , wherein the coating comprises: 
 25-75 wt. % water;    30-70 wt. % calcium carbonate;    0-30 wt. % filler;    2-10 wt. % latex emulsion; and    0-10 wt. % additives.    
     
     
         7 . The gypsum board of  claim 6 , wherein the filler comprises one or more of mica, talc, clay, and limestone.  
     
     
         8 . The gypsum board of  claim 6 , wherein the composition further comprises a pigment in an amount sufficient to provide a desired tint to the coating.  
     
     
         9 . The gypsum board of  claim 1 , wherein the coating comprises: 
 10-60 vol. % water;    50-90 vol. % calcined gypsum;    0.1-10 vol. % binder;    0-50 vol. % limestone;    0-10 vol. % clay;    0-30 vol. % other fillers; and    0-10 vol % additives.    
     
     
         10 . The gypsum board of  claim 9 , wherein the composition further comprises a pigment in an amount sufficient to provide a desired tint to the coating.  
     
     
         11 . The gypsum board of  claim 9 , wherein the facing sheet is made from unbleached grey paper and the coating is comprised primarily of calcium carbonate or gypsum.  
     
     
         12 . The gypsum board of  claim 9 , wherein the facing sheet of the completed board has a level 5 finish, as defined herein.  
     
     
         13 . A gypsum board having a coating applied thereon, the gypsum board comprising: 
 a gypsum core having a first side and a second side and a facing sheet disposed on the first side; and    a coating disposed on at least a portion of the facing sheet such that the facing sheet has a level 5 finish after manufacture and prior to applying the gypsum board in an intended application.    
     
     
         14 . The gypsum board of  claim 13 , wherein the coating is primarily calcium carbonate or gypsum.  
     
     
         15 . A gypsum board having a coating applied thereon, the gypsum board comprising: 
 a gypsum core having a first side and a second side and a facing sheet disposed on the first side; and    a coating disposed on at least a portion of the facing sheet such that the facing sheet has a level 4 finish after manufacture and prior to applying the gypsum board in an intended application.    
     
     
         16 . A kit comprising a quantity of joint compound and a plurality of gypsum boards having a coating applied thereon, each of the gypsum boards comprising: 
 a gypsum core having a first side and a second side and a facing sheet disposed on the first side; and    a coating disposed on at least a portion of the facing sheet; and    the coating is a diluted form of the joint compound.    
     
     
         17 . The kit of  claim 16 , wherein the coating is primarily calcium carbonate or gypsum.  
     
     
         18 . The kit of  claim 16 , wherein the coating is such that the facing sheet has a level 5 finish after manufacture and prior to applying the gypsum board in an intended application.  
     
     
         19 . The kit of  claim 18 , wherein the coating is primarily calcium carbonate or gypsum.  
     
     
         20 . A method of producing a coated gypsum board, the method comprising: 
 depositing a gypsum slurry to form a wet gypsum board having a gypsum core;    applying a coating to the wet gypsum board; and    drying the wet gypsum board,    wherein the step of applying the coating occurs prior to the step of drying and the coating penetrates through at least a portion of the facing sheet and into at least a portion of the gypsum core.    
     
     
         21 . The method of  claim 20 , wherein the coating is a diluted joint compound.  
     
     
         22 . A method of producing a coated gypsum board, the method comprising: 
 depositing a gypsum slurry to form a wet gypsum board having a gypsum core;    applying a coating to the wet gypsum board; and    drying the wet gypsum board,    wherein the step of applying the coating occurs prior to the step of drying and the coating is a diluted joint compound.    
     
     
         23 . A method of producing a coated gypsum board, the method comprising: 
 depositing a gypsum slurry to form a wet gypsum board having a gypsum core;    applying a coating to the wet gypsum board; and    drying the wet gypsum board,    wherein the step of applying the coating occurs prior to the step of drying and the coated board has a level 5 finish prior to assembly in its intended use.    
     
     
         24 . A method of making a wall, comprising: 
 depositing a gypsum slurry to form a wet gypsum board having a gypsum core;    applying a coating to the gypsum board;    fastening the coated gypsum board to a support structure to form the wall; and    taping and finishing seams between adjacent coated gypsum boards using a joint compound having substantially a same solids content as the composition of the coating.    
     
     
         25 . A method of making a wall, comprising: 
 depositing a gypsum slurry to form a wet gypsum board having a gypsum core;    applying a coating to the wet gypsum board;    drying the wet gypsum board, wherein the step of applying the coating occurs prior to the step of drying;    fastening the coated gypsum board to a support structure to form the wall; and    taping and finishing seams between adjacent coated gypsum boards using a joint compound having a composition substantially similar to the composition of the coating.    
     
     
         26 . A method of making a wall, comprising: 
 fastening a coated gypsum board to a support structure to form the wall, wherein the board is in accordance with one of claims  1 ,  13 , or  15 ; and    taping and finishing seams between adjacent coated gypsum boards using a joint compound having substantially a same solids content as the composition of the coating.    
     
     
         27 . A method of making a wall, comprising: 
 fastening a coated gypsum board to a support structure to form the wall, wherein the board is made in accordance with one of claims  20 ,  22 , or  23 ; and    taping and finishing seams between adjacent coated gypsum boards using a joint compound having a composition substantially similar to the composition of the coating.