Fabric reinforcement and cementitious boards faced with same

• US 20050009428A1
• Filed: 07/09/2003
• Published: 01/13/2005
• Est. Priority Date: 07/09/2003
• Status: Active Grant

• Current Assignee: Saint-Gobain Adfors Canada Ltd.
• Original Assignee: Saint-Gobain Technical Fabrics Europe
• Inventors: Porter, John Frederick, Roberts, Geraint
• Granted Patent: US 7,354,876 B2
• Time in Patent Office: Days
• US Class Current: 442/129
• CPC Class Codes: B32B 13/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2315/06 Concrete
• CPC Class Codes: B32B 2315/085 Glass fiber cloth or fabric
• CPC Class Codes: B32B 2315/18 Plaster
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 37/24 with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate B32B37/15 takes precedence
• CPC Class Codes: B32B 5/02 characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 20/1029 Macromolecular compounds
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: D03D 15/267 Glass
• CPC Class Codes: D10B 2505/02 Reinforcing materials; Prepregs
• CPC Class Codes: E04C 5/07 Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal metal elements with non-structural coatings E04C5/01
• CPC Class Codes: Y10T 428/24124 Fibers
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/249932 Fiber embedded in a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
• CPC Class Codes: Y10T 442/172 Coated or impregnated
• CPC Class Codes: Y10T 442/198 Coated or impregnated
• CPC Class Codes: Y10T 442/2041 : Two or more non-extruded coatings or impregnations
• CPC Class Codes: Y10T 442/2049 : Each major face of the fabric has at least one coating or impregnation
• CPC Class Codes: Y10T 442/2107 : At least one coating or impregnation contains particulate material
• CPC Class Codes: Y10T 442/2369 : Coating or impregnation improves elasticity, bendability, resiliency, flexibility, or shape retention of the fabric
• CPC Class Codes: Y10T 442/2484 : Coating or impregnation is water absorbency-increasing or hydrophilicity-increasing or hydrophilicity-imparting
• CPC Class Codes: Y10T 442/2574 : Acid or alkali resistant
• CPC Class Codes: Y10T 442/2926 : Coated or impregnated inorganic fiber fabric
• CPC Class Codes: Y10T 442/2934 : Coating or impregnation contains vinyl polymer or copolymer
• CPC Class Codes: Y10T 442/2992 : Coated or impregnated glass fiber fabric
• CPC Class Codes: Y10T 442/3065 : Including strand which is of specific structural definition
• CPC Class Codes: Y10T 442/361 : At least one layer is derived from water-settable material [e.g., cement, gypsum, etc.]
• CPC Class Codes: Y10T 442/3797 : Coating or impregnation is derived from a water-settable material [e.g., cement, gypsum, etc.]
• CPC Class Codes: Y10T 442/425 : Including strand which is of specific structural definition
• CPC Class Codes: Y10T 442/608 : Including strand or fiber material which is of specific structural definition

Abstract

Fabric and reinforcements are provided by this invention which, in a first embodiment, include a plurality of warp yarns having a first twist (turns/inch) and a plurality of weft yarns having a second twist which is greater than the first twist. A coating is applied over a substantial portion of the warp and weft yarns after they are assembled or laid together, so as to produce a weight distribution ratio of less than about 2.0:1, based upon the weight of the resinous coating of the weft yarns over the weight of the resinous coating on the warp yarns. This can be achieved, in substantial part, due to the difference in the twist ratios of the warp and weft yarns, which difference permits a more uniform coating to be applied. Further embodiments of this invention include a cementitious board and methods of making a coated fabric and cementitious board.

Claims

1. A fabric reinforcement useful in reinforcing an alkaline matrix comprising:

(a) a plurality of warp yarns having a first twist (turns/inch);

(b) a plurality of weft yarns having a second twist which is greater than said first twist; and

(c) a resinous coating disposed over a substantial portion of said warp and weft yarns after they have been assembled or laid together, such as to produce a coating weight distribution ratio of less than about 2.0;

1, based upon the weight of the resinous coating on the weft yarns over the weight of the resinous coating on the warp yarns.

2. The fabric of claim 1 wherein said warp yarns comprise a first twist of about 0-0.5 turns/inch.

3. The fabric of claim 2 wherein said weft yarns comprise a second twist of about 0.5-1.3 turns/inch.

4. The fabric of claim 1 wherein said warp yarns, said weft yarns, or both, comprise glass fibers.

5. The fabric of claim 1 wherein said warp yarn and weft yarns are assembled into one or more of:

a woven fabric, knit fabric, laid scrim fabric, or braided fabric.

6. The fabric of claim 1 wherein said resinous coating comprises a pvc-based plastisol.

7. The fabric of claim 1 wherein said plurality warp yarns are drawn in tension prior to the application of said resinous coating.

8. The fabric of claim 1 wherein said warp yarns are selected to include, or are treated with, a hydrophilic agent, prior to a water based coating, or an oleophilic agent prior to a pvc plastisol coating

9. The fabric of claim 1 wherein said weft yarns are selected to include, or are treated with, an oleophobic agent prior to a pvc-based plastisol coating, or a hydrophobic agent prior to a water based coating.

10. A reinforced cementitious board comprising:

(a) a cementitious core; and

(b) a reinforcing fabric disposed on at least one face of said cementitious core;

said reinforcing fabric including;

(i) a plurality of warp yarns having a first twist (turns/inch);

(ii) a plurality of weft yarns having a second twist which is greater than said first twist; and

(c) a resinous coating applied to said reinforcing fabric in a coating weight distribution ratio of less than about 2.0;

1 based upon the weight of the resinous coating on the weft yarns, over the weight of the resin on the warp yarns.

11. The cementitious board of claim 10 wherein said cementitious core comprises Portland cement.

12. The cementitious board of claim 10 wherein said reinforcing fabric comprises a woven, braided, nonwoven mesh-type or knitted fabric.

13. The cementitious board of claim 10 wherein said first twist of said warp yarns is about 0-0.3 turns/inch.

14. The cementitious board of claim 13 wherein said second twist of said weft yarns is about 0.7-1.0 turns/inch.

15. The cementitious board of claim 10 wherein said resinous coating comprises an alkali-resistant resin.

16. A reinforced cementitious board comprising:

(a) a cementitious core comprising Portland cement; and

(b) a reinforcing fabric disposed generally around and embedded into a portion of said cementitious core;

said reinforcing fabric being composed of a multifilament yarn-based woven, braided, nonwoven mesh-type, or knitted fabric which includes;

(i) a plurality of warp yarns having a first twist (turns/inch);

(ii) a plurality of weft yarns having a second twist, said second twist being greater than said first twist; and

(c) an alkali resistant resinous coating applied to said plurality of warp and said plurality of weft yarns after they have been assembled or laid together, such as to produce a coating weight distribution ratio of less than about 2.0;

1 based upon the weight of the resinous coating on the weft yarns over the weight of the resinous coating on the warp yarns.

17. The cementitious board of claim 16 wherein said reinforcing fabric comprises sized glass fibers.

18. The cementitious board of claim 16 wherein said warp yarns have a twist of about 0-0.3 turns/inch.

19. The cementitious board of claim 18 wherein said weft yarns have a twist of about 0.7-1 turns/inch.

20. The cementitious board of claim 16 wherein said alkali resistant coating provides alkali resistance to said reinforcing fabric beyond one year in a Portland cement board.

21. The cementitious board of claim 20 wherein said resinous coating comprises a pvc matrix having an oil phase distributed therein.

22. A multifilament yarn-based woven, braided, nonwoven mesh-type, or knitted fabric comprising:

(a) a plurality of warp yarns having a first twist (turns/inch);

(b) a plurality of weft yarns having a second twist, said second twist being greater than said first twist; and

(c) a resinous coating applied to said plurality of warp and said plurality of weft yarns while the warp yarns are being pulled in tension in a machine direction, such that the weft yarns absorb less of said resinous coating than said weft yarns would absorb if the second twist of said weft yarns was equal to the first twist of said warp yarns.

23. A cementitious board incorporating the multifilament yarn-based woven, braided, non-woven mesh-type or knitted fabric of claim 22.

24. The fabric of claim 22 wherein said resinous coating comprises a alkali resistant resin.

25. A multifilament yarn-based woven, braided, nonwoven mesh-type, or knitted reinforcement comprising:

(a) a plurality of warp yarns containing a glass filament having a first twist of about 0-0.3 turns/inch.

(b) a plurality of weft yarns containing a glass filament having a second twist of about 0.7-1.0 turns/inch; and

(c) a protective resinous coating applied to said plurality of warp and weft yarns after they have been assembled or laid together, such as to produce a weight distribution ratio of less than about 2.0;

1 based upon the weight of the resinous coating on the weft yarns over the weight of the resinous coating on the warp yarns, said weight distribution ratio created in substantial part by the difference in twists of said warp and weft yarns.

26. A multifilament yarn-based woven, braided, non-woven mesh-type, or knitted fabric comprising:

(a) a plurality of warp yarns having a first twist (turns/inch);

(b) a plurality of weft yarns having a second twist; and

(c) a resinous coating applied to said plurality of warp yarns and said plurality of weft yarns after they have been assembled or laid together, such as to produce a coating weight distribution ratio of less than about 2.0;

1 based upon the weight of the resinous coating on the weft yarns over the weight of the resinous coating on the warp yarns.

27. The fabric of claim 26 wherein said first twist ratio is less than said second twist ratio.

28. The fabric of claim 26 wherein said weft yarns have a lower hydrophilicity than said warp yarns.

29. The fabric of claim 26 wherein said tension is also applied to said weft yarns.

30. A method of making a coated fabric comprising:

(a) providing a plurality of warp yarns having a first twist (turns/inch);

(b) assembling a plurality of weft yarns with said warp yarns, said weft yarns having a second twist;

said second twist being greater than said first twist; and

(c) applying a resinous coating to assembly of said plurality of warp yarns and plurality of weft yarns, whereby the weight of the resinous coating on the weft yarns over the weight of the resinous coating on the warp yarns is less than about 2.0;

1.

31. The method of claim 30 wherein said weft yarns, warp yarns, or both, comprise glass filaments.

32. The method of claim 30 wherein the weight of the resinous coating on the weft yarns over the weight of the resinous coating on the warp yarns is less than about 1.5:

1.

33. The method of claim 30 wherein said resinous coating comprises a plastisol.

34. A method of making a cementitious board, comprising:

(a) providing a cementitious slurry;

(b) depositing said cementitious slurry onto a moving reinforcing fabric, said reinforcing fabric comprising a plurality of warp yarns having a first twist (turns/inch), a plurality of weft yarns having a second twist which is greater than said first twist; and

a resinous coating applied to said reinforcing fabric in a coating weight distribution ratio of less than about 2.0;

1, based upon the weight of the resinous coating on the weft yarns, over the weight of the resinous coating on the warp yarns;

(c) shaping said cementitious slurry and said reinforcing fabric into a board, whereby said reinforcing fabric is disposed on at least one face thereof, and

(d) permitting said cementitious slurry to set.

35. The method of claim 34 wherein said forming step is continuous or discontinuous.