One aspect of the disclosure is a plaster board having a first edge and an opposed second edge, and a third edge and an opposed fourth edge. The plaster board includes a first layer of hardened plaster material including a first surface and an opposed second surface, and a second layer of hardened plaster material including a first surface and an opposed second surface. The second layer of hardened plaster material is stacked against the first layer such that their first surfaces face one another. The first layer and the second layer together define the first, second, third, and fourth edges of the plaster board. The plaster board also includes a viscoelastic polymer disposed between the first surfaces of the first and second layers of hardened plaster material. The viscoelastic polymer does not extend substantially to the first, second, third, and fourth edges of the plaster board.

The present invention is directed to an improved gypsum board, such as an improved sound damping gypsum board, and a method of making such gypsum board. For instance, the method comprises: providing a first encasing layer and a first sound damping layer on the first encasing layer wherein the sound damping layer includes at least 50 wt. % of a first sound damping polymer; depositing a gypsum slurry comprising stucco and water on the sound damping layer to form a gypsum core; providing a second encasing layer on the gypsum slurry; and allowing the stucco to convert to calcium sulfate dihydrate.

A method of making a concrete panel board is provided. The method includes the steps of: (a) providing a substrate; (b) applying a primer layer to the substrate; (c) drying the board after step b; (d) applying a thinset mortar layer to the primer layer; (e) drying the board after step d; (f) applying a plaster layer to the thinset mortar layer; (g) drying the board after step f; and (h) applying a sealant layer to the plaster layer.

Fiber-reinforced coated mats and fiber-reinforced coated mat-faced panels are provided herein, along with methods for making the same. Fiber-reinforced coated mats include a mat with a fiber-reinforced coating on one surface. Fiber-reinforced coated mat-faced panels include a fiber-coated mat and a panel material in contact with a surface of the mat opposite the fiber-reinforced coating. Methods include applying a fiber-reinforced coating to a surface of a mat to form a coated mat and drying the coated mat to cure the fiber-reinforced coating. Some methods also include combining the mat with a panel material to form a mat-faced panel.

Self-sealing fasteners and associated building panels, systems, and methods are provided. In one aspect, a fastener includes an elongated fastener body with an external surface extending between the first end and the second end, and a coating material disposed on at least a portion the external surface. In another aspect, a fastener includes an elongated fastener body with an external surface extending between the first end and the second end, and a polymer annulus surrounding at least a portion of the external surface of the of the elongated fastener body at or adjacent the head of the fastener.

The present disclosure is directed to a method of manufacturing gypsum board as well as the resulting gypsum board. The method comprises providing a gypsum slurry with a shrinkage-reducing additive comprising a metal salt of an acid, a silica, or a mixture thereof. As a result, the gypsum board includes gypsum and a shrinkage-reducing additive comprising a metal salt of an acid, a silica, or a mixture thereof. The gypsum board exhibits an area shrinkage of less than 10%.

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.

In general, the present invention is directed to a building panel, such as a gypsum board, comprising a core having a first side and a second side opposing the first side and at least one facing material having a coating comprising at least one fungicide, at least one polymeric binder, and at least one pigment. The panel satisfies at least one of the following: the board exhibits a rating of 2 or less when tested in accordance to ASTM G21-15 or the board exhibits a rating of at least 8 when tested in accordance to ASTM D3273-16. The panel may also exhibit at least a Level 3 finish.

This invention generally relates to phase-change materials (“PCM” or “PCM materials”) made from colloidally-protected wax-based microstructures. This invention also relates to such PCM materials configured in various physical forms. This invention further relates to a process of configuring such PCM materials for a variety of end-use applications in which dampening of temperature fluctuations by absorption and desorption of heat is desired. This invention further relates to preparing colloidally-protected wax-based microstructures in particulate form that function as PCM materials.

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.