System and method for constructing composite building boards using thermoplastic films

• US 10,457,027 B2
• Filed: 08/04/2015
• Issued: 10/29/2019
• Est. Priority Date: 06/07/2010
• Status: Active Grant

• Current Assignee: Certainteed Gypsum Incorporated (Compagnie De Saint-Gobain)
• Original Assignee: Certainteed Gypsum Incorporated (Compagnie De Saint-Gobain)
• Inventors: Hauber, Robert J., Boydston, Gerald D.
• Primary Examiner(s): Del Sole, Joseph S
• Assistant Examiner(s): Robitaille, John
• Application Number:
  US14/817,740
• Publication Number:
  US 20160052248A1
• Time in Patent Office: 1,547 Days
• Field of Search: 156 39, 156 44
• CPC Class Codes: B28B 19/0046 to plastics
• CPC Class Codes: B28B 19/0092 to webs, sheets or the like, e.g. of paper, cardboard
• CPC Class Codes: B28B 23/0006 the reinforcement consisting of aligned, non-metal reinforcing elements
• CPC Class Codes: B32B 13/04 comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a glass layer B32B17/06
• CPC Class Codes: B32B 13/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2037/1215 Hot-melt adhesive
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/212 Electromagnetic interference shielding
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/536 Hardness
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2307/712 Weather resistant
• CPC Class Codes: B32B 2307/7145 Rot proof, resistant to bacteria, mildew, mould, fungi
• CPC Class Codes: B32B 2307/732 Dimensional properties
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 37/0053 : Constructional details of laminating machines comprising rollers; Constructional features of the rollers
• CPC Class Codes: B32B 37/1207 : Heat-activated adhesive B32B37/04 takes precedence
• CPC Class Codes: B32B 37/14 : characterised by the properties of the layers
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04C 2/043 : of plaster E04C2/049 takes precedence
• CPC Class Codes: E04C 2/246 : combinations of materials fully covered by E04C2/16 and E04C2/20
• CPC Class Codes: E04C 2/28 : combinations of materials fully covered by groups E04C2/04 and E04C2/08

Abstract

Disclosed are building board manufacturing techniques that minimize the build-up of slurry on associated forming equipment and also produce panels with enhanced physical properties. The methods involve applying a dissolvable film laminate to one or more fiber mats at the outset of the forming process. In the undissolved state, the film acts as a containment envelope for the gypsum slurry and any free floating glass fibers. During subsequent curing, the film is dissolved by vaporized water. In its dissolved state, the film is liquefied and coats the fibers of the underlying mat. This results in a building board with improved physical properties.

Claims

1. A system for manufacturing building boards along a production line, the system comprising:

a roll of a first glass mat, the first mat having interior and exterior surfaces;

a coating apparatus and a supply of a hot melt thermoplastic, the coating apparatus being configured to apply a thin layer of the hot melt thermoplastic on the exterior surface of the first glass mat;

guide rollers for inverting the first glass mat after the application of the hot melt thermoplastic, the guide rollers configured to allow the applied thermoplastic coating to partially cool;

a series of forming tables positioned downstream of the coating apparatus, the guide rollers configured to deliver the first mat with the thermoplastic coating to a forming table, wherein the adhered thermoplastic coating faces the forming table and the interior surface of the first mat is exposed.

2. The system as described in claim 1 further comprising a mixer positioned downstream of the coating apparatus, the mixer storing a volume of slurry and having an outlet for depositing the slurry over the interior surface of the first mat, wherein the thermoplastic coating acts as a barrier in preventing deposited slurry from contacting the underlying forming belt.

3. The system as described in claim 2 configured such that the deposited gypsum slurry is permitted to fully penetrate the first mat, wherein the deposited gypsum slurry forms a small layer between the contacting surface of the first mat and the thermoplastic coating.

4. The system as described in claim 2 further comprising a roll of a second mat, configured to apply the second mat over the gypsum slurry, wherein the first mat, the second mat, the gypsum slurry and the thermoplastic coating together form a panel.

5. The system as described in claim 1 wherein the coating apparatus is in-line with the production line.

6. The system as described in claim 1 wherein the coating apparatus is a curtain coater.

7. The system as described in claim 1 wherein the coating apparatus is a spray coater.

8. The system as described in claim 1 wherein the coating apparatus is a knife coater.

9. The system as described in claim 1 wherein the coating apparatus is a slot die.

10. The system as described in claim 1 configured to provide the thermoplastic in a layer having a thickness weight of between approximately 0.01 g/sqft to 45 g/sqft.

16. A system as described in claim 1 wherein the first mat and the second mat are precoated with thermoplastic.

17. A system as described in claim 1 wherein either the first mat or the second mat is precoated with thermoplastic.

11. A system for manufacturing building boards, the system utilizing a forming table and a mixer for supplying a slurry, the system further comprising:

a roll of a mat, the mat having interior and exterior surfaces;

a coating apparatus positioned in-line with the forming table and the mixer, the coating apparatus containing a supply of a thermoplastic and configured to supply a layer of the thermoplastic on the exterior surface of the mat.

12. The system as described in claim 11 further comprising guide rollers for inverting the mat after the application of the thermoplastic, the guide rollers being configured to allow the applied thermoplastic coating to partially cool.

13. The system as described in claim 11 wherein the thermoplastic is a hot melt thermoplastic.

14. The system as described in claim 11 further comprising a curtain coater configured to apply the thermoplastic.

15. The system as described in claim 11 wherein the thermoplastic is a molten acrylonitrile butadiene styrene (ABS).