Exterior sheathing panel with integrated air/water barrier membrane

Abstract

An exterior sheathing cementitious panel which prevents water penetration and air leakage is provided methods for manufacturing exterior sheathing cementitious panels with a highly efficient integrated air/water barrier membrane are provided as well.

1 - 17 . (canceled) 
     
     
         18 . A liquid coating composition, which, when cured, forms a water vapor permeable integrated air and water barrier membrane coating for use on an exterior surface of a sheathing panel, the coating composition comprising:
 from 30 to 70% by weight of a polymeric binder comprising a polyacrylate, polyurethane, silicone emulsion, polystyrene, styrene acrylic copolymer, or any combination thereof, and   from 20 to 50% by weight of calcium carbonate.   
     
     
         19 . The coating composition of  claim 18 , wherein the coating composition further comprises at least one additive selected from the group consisting of a dispersant, a defoamer, a pigment, a thickener, a preservative, a pH adjuster, an emulsion stabilizer, a wetting and leveling agent, and a cross linker. 
     
     
         20 . The coating composition of  claim 18 , wherein the coating composition further comprises from 0.1 to 5% by weight of a cross linker. 
     
     
         21 . The coating composition of  claim 20 , wherein the cross linker comprises at least one of: zinc oxide, a zinc metal ion, a stabilized ammonium zirconium carbonate containing one or more anionic hydroxylated zirconium polymers, or an epoxy functional silane. 
     
     
         22 . The coating composition of  claim 19 , wherein the cross linker comprises at least one of: zinc oxide, a zinc metal ion, a stabilized ammonium zirconium carbonate containing anionic hydroxylated zirconium polymers, or an epoxy functional silane. 
     
     
         23 . The coating composition of  claim 20 , wherein the coating composition further comprises from 0.1 to 5% by weight of a wetting and leveling agent. 
     
     
         24 . The coating composition of  claim 23 , wherein the wetting and leveling agent comprises at least one of: a sulfosuccinate, a polyether modified siloxane, a urea modified polyurethane, or a modified urea ammonium salt of an acrylate copolymer. 
     
     
         25 . The coating composition of  claim 18 , wherein the coating composition further comprises from 0.1 to 5% by weight of a wetting and leveling agent. 
     
     
         26 . The coating composition of  claim 25 , wherein the wetting and leveling agent comprises at least one of the following: a sulfosuccinate, a polyether modified siloxane, a urea modified polyurethane, or a modified urea ammonium salt of an acrylate copolymer. 
     
     
         27 . The coating composition of  claim 18 , wherein the coating composition further comprises an antimicrobial agent selected from the group consisting of 2-(4-thiazolyl) benzimidazole, silver zeolyte, zinc oxide, and zinc pyrithione. 
     
     
         28 . The coating composition of  claim 18 , wherein the polyacrylate comprises an acrylic latex. 
     
     
         29 . A water vapor permeable integrated air and water barrier membrane coating formed from the coating composition of  claim 18 . 
     
     
         30 . The water vapor permeable integrated air and water barrier coating of  claim 29  having a dry thickness ranging from 10 mils to 90 mils. 
     
     
         31 . The water vapor permeable integrated air and water barrier coating of  claim 29  having no blisters. 
     
     
         32 . A water vapor permeable integrated air and water barrier membrane coating suitable for use on an exterior surface of a cementitious sheathing panel, the coating formed from a liquid polymer coating composition, the coating composition comprising:
 from 30 to 70% by weight of a polymeric binder comprising a polyacrylate, polyurethane, silicone emulsion, polystyrene, styrene acrylic copolymer, or any combination thereof, and   from 20 to 50% by weight of calcium carbonate,   wherein, when dried, the coating has a thickness from 10 mils to 90 mils.   
     
     
         33 . The coating of  claim 32 , wherein the coating is formed from the coating composition further comprising at least one additive selected from the group consisting of an emulsion stabilizer, a wetting and leveling agent, and a cross linker. 
     
     
         34 . The coating of  claim 32 , wherein the coating is formed from the coating composition further comprising from 0.1 to 5% by weight of a cross linker. 
     
     
         35 . The coating of  claim 32 , wherein the coating is formed from the coating composition further comprising from 0.1 to 5% by weight of a wetting and leveling agent. 
     
     
         36 . The coating of  claim 32 , wherein the polyacrylate comprises an acrylic latex. 
     
     
         37 . The coating of  claim 32 , wherein the coating is blister-free. 
     
     
         38 . A liquid coating composition, which, when cured, forms an integrated air and water barrier membrane coating for use on an exterior surface of a sheathing panel, the coating composition comprising:
 a polymeric binder comprising an acrylic latex, an acrylic styrene co-polymer, a styrene-butadiene dispersion, or combinations thereof, and   a filler comprising talc, calcium carbonate, or combinations thereof,   wherein the coating composition is formulated such that air infiltration and exfiltration is prevented or minimized through a sheathing panel substrate and the permeability of a sheathing panel substrate to water vapors is minimized.   
     
     
         39 . The coating composition of  claim 21 , wherein the coating composition further comprises at least one additive selected from the group consisting of a dispersant, a defoamer, a pigment, a thickener, a preservative, a wetting and leveling agent, a pH adjuster, and an emulsion stabilizer. 
     
     
         40 . An integrated air and water barrier membrane coating formed from the coating composition of  claim 21 . 
     
     
         41 . The coating of  claim 23 , wherein the integrated air and water barrier membrane coating reduces air infiltration through the panel by at least 50%. 
     
     
         42 . The coating of  claim 23 , wherein the integrated air and water barrier membrane coating is formulated in a manner to prevent or minimize air infiltration and exfiltration through a sheathing panel substrate and the water vapor permeance rate through a sheathing panel substrate is minimized.