Fiber-cement/gypsum laminate

• US 20080022627A1
• Filed: 07/10/2007
• Published: 01/31/2008
• Est. Priority Date: 10/08/1999
• Status: Abandoned Application

• Current Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Original Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Inventors: Fisher, Mark, Gleeson, James, Merkley, Donald
• Application Number:
  US11/825,870
• Publication Number:
  US 20080022627A1
• Time in Patent Office: Days
• US Class Current: 52/745.19
• CPC Class Codes: B32B 13/00 Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
• CPC Class Codes: B32B 13/02 with fibres or particles being present as additives in the layer
• CPC Class Codes: B32B 13/08 of paper or cardboard
• CPC Class Codes: B32B 13/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2329/00 Polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 27/02 in the form of fibres or filaments not used
• CPC Class Codes: B32B 27/06 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 layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/10 of paper or cardboard
• CPC Class Codes: B32B 29/00 Layered products comprising a layer of paper or cardboard
• CPC Class Codes: B32B 29/02 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: C04B 18/241 Paper, e.g. waste paper; Paper pulp
• CPC Class Codes: C04B 2111/0062 Gypsum-paper board like materials
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 41/5085 Calcium sulfate cements
• CPC Class Codes: E04C 2/043 of plaster E04C2/049 takes precedence
• CPC Class Codes: E04C 2/049 completely or partially of insulating material, e.g. cellular concrete or foamed plaster
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/24959 : of adhesive layers
• 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 428/249967 : Inorganic matrix in void-containing component
• CPC Class Codes: Y10T 428/26 : Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/2904 : Staple length fiber
• CPC Class Codes: Y10T 428/2913 : Rod, strand, filament or fiber

Abstract

A building material (40) is provided comprising fiber-cement (10) laminated to gypsum (20) to form a single piece laminate composite. This single piece laminate composite exhibits improved fire resistance and surface abuse and impact resistance, but achieves these properties without the excessive weight and thickness of two piece systems. Additionally, because of the reduced thickness, the preferred laminate building material is easier to cut and is quicker and easier to install than two piece systems. Furthermore, forming the fiber-cement and gypsum into a single piece laminate eliminates the need to install two separate pieces of building material, thereby simplifying installation. In one embodiment, a ⅝″ thick laminate composite is provided comprising a ½″ thick gypsum panel laminated to a ⅛″ thick fiber-cement sheet, the laminate composite having a fire resistance rating of 1 hour when measured in accordance with ASTM E119.

Claims

1-11. -11. (canceled)

12. A method for manufacturing a composite building material comprising:

applying an adhesive to a face of a gypsum layer; and

laminating a fiber cement layer to the adhesive.

13. The method of claim 12, wherein the gypsum layer is about ½

″

thick.

14. The method of claim 12, wherein the gypsum layer is a type X fire resistant gypsum board.

15. The method of claim 12, wherein the fiber cement layer is about ⅛

″

thick.

16. The method of claim 12, wherein the fiber cement layer is a pre-fabricated fiber cement sheet.

17. The method of claim 12, wherein the fiber cement layer comprises cellulose fiber

18. The method of claim 12, further comprising sanding the fiber cement layer.

19. The method of claim 12, wherein the laminating comprises pressing the gypsum layer and fiber cement layer together.

20. The method of claim 12, wherein the adhesive is selected from the group consisting of organic adhesives, inorganic adhesives, polyvinyl acetate, water-based polymeric adhesives, solvent-based adhesives, thermoset adhesives, natural polymers, modified starches, liquid moisture cure adhesives, reactive hot melt adhesives, polyurethane, heat or fire resistant adhesives, pressure sensitive adhesives, and combinations thereof.

21. The method of claim 12, wherein the adhesive is applied by a roll-coater process.

22. The method of claim 12, wherein the adhesive has a wet film thickness of from about 4.5 mil to about 6 mil.

23. The method of claim 12, further comprising tapering an edge of the composite building panel.

24. The method of claim 12, further comprising sealing the surface of the composite building panel.

25. The method of claim 24, wherein at least the fiber cement surface of the composite building panel is sealed with an acrylic sealer.

26. The method of claim 12, wherein the composite building material has a fire resistance rating of at least an hour according to ASTM E 119-98.