Plastic Coated Composite Building Boards and Method of Making Same

• US 20100055431A1
• Filed: 06/08/2009
• Published: 03/04/2010
• Est. Priority Date: 08/29/2008
• Status: Active Grant

• Current Assignee: Certainteed Gypsum Incorporated (Compagnie De Saint-Gobain)
• Original Assignee: Certainteed Gypsum Incorporated (Compagnie De Saint-Gobain)
• Inventors: College, John
• Granted Patent: US 8,486,516 B2
• Time in Patent Office: Days
• US Class Current: 428/218
• 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: B29D 99/0021 provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix
• 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 13/08 of paper or cardboard
• CPC Class Codes: B32B 13/12 of synthetic resin
• CPC Class Codes: B32B 13/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2250/44 Number of layers variable across the laminate
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/044 Water-setting substance, e.g. concrete, plaster
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2264/10 Inorganic particles
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/402 Coloured
• CPC Class Codes: B32B 2307/414 : Translucent
• CPC Class Codes: B32B 2307/50 : having particular mechanical properties
• CPC Class Codes: B32B 2307/514 : Oriented
• CPC Class Codes: B32B 2307/536 : Hardness
• CPC Class Codes: B32B 2307/54 : Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/554 : Wear resistance
• CPC Class Codes: B32B 2307/558 : Impact strength, toughness
• CPC Class Codes: B32B 2307/58 : Cuttability
• CPC Class Codes: B32B 2307/5825 : Tear resistant
• CPC Class Codes: B32B 2307/71 : Resistive to light or to UV
• CPC Class Codes: B32B 2307/7265 : Non-permeable
• CPC Class Codes: B32B 2419/00 : Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/10 : of paper or cardboard
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/28 : comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
• CPC Class Codes: B32B 27/30 : comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/306 : comprising vinyl acetate or vinyl alcohol (co)polymers
• CPC Class Codes: B32B 27/308 : comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 3/04 : characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/22 : characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/10 : at least one layer having inter-reactive properties
• CPC Class Codes: C04B 14/42 : Glass
• CPC Class Codes: C04B 2111/00405 : Materials with a gradually increasing or decreasing concentration of ingredients or property from one layer to another
• CPC Class Codes: C04B 2111/00612 : as one or more layers of a layered structure
• CPC Class Codes: C04B 24/2623 : Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 24/2682 : Halogen containing polymers, e.g. PVC
• CPC Class Codes: C04B 24/42 : Organo-silicon compounds
• CPC Class Codes: C04B 28/14 : containing calcium sulfate cements gypsum-paper plates E04C
• CPC Class Codes: E04C 2/043 : of plaster E04C2/049 takes precedence
• CPC Class Codes: E04C 2/06 : reinforced
• CPC Class Codes: Y10T 428/24992 : Density or compression of components
• CPC Class Codes: Y10T 428/249955 : Void-containing component partially impregnated with adjacent component
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31678 : Of metal
• CPC Class Codes: Y10T 428/31993 : Of paper
• CPC Class Codes: Y10T 442/20 : Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
• CPC Class Codes: Y10T 442/2926 : Coated or impregnated inorganic fiber fabric
• CPC Class Codes: Y10T 442/604 : Strand or fiber material is glass

Abstract

Disclosed are composite building boards and associated manufacturing methods. The composite boards may include, for example, one or more slurry layers with embedded fibrous mats. An exterior plastic coating is mechanically adhered to the underlying slurry layer. The plastic layer chemically bonds and cross-links with polymer additives within the slurry layer. The result is an integrated polymer matrix with greatly improved durability and surface strength.

Claims

1. A composite building board comprising:

upper and lower mats formed from non-woven, randomly aligned glass fibers held together by a binder, the mats being porous and having interior and exterior surfaces;

a thermoplastic pre-coating applied to the randomly aligned glass fibers of the upper and lower mats;

upper and lower dense slurry layers coating and penetrating the upper and lower mats respectively, whereby the exterior surface of each mat is substantially covered by slurry, a slurry boundary layer defined by the slurry covering the exterior surface of each mat, the boundary layer having a thickness of between approximately 0.01 to 2.0 mm, the upper and lower dense slurry layers including a polymeric additive that increases the strength of the composite board and that bonds with the thermoplastic pre-coating;

a core slurry layer extending between and bonded to the upper and lower dense slurry layers, the core slurry layer having a density that is less than the density of the upper and lower dense slurry layers, the core slurry layer including a polymeric additive that bonds with the polymeric additive of the upper and lower slurry layers and the thermoplastic pre-coating;

a hot melt thermoplastic coating with a melting point between 100°

to 500°

F. mechanically adhered to the slurry boundary layer, the thermoplastic coating also cross-linking with the polymeric additive of the upper, lower and core slurry layers and the thermoplastic pre-coating to form a composite polymer matrix, the thermoplastic coating having a thickness of between 0.01 to 500 mils.

2. A composite building board comprising:

a porous mat having interior and exterior surfaces;

a cementitious slurry layer penetrating the porous mat and substantially covering the exterior surface, a boundary layer defined by the slurry substantially covering the exterior surface of the porous mat;

a polymer coating mechanically and chemically adhered to the boundary layer and forming a polymer matrix within the composite building board.

3. The composite building board described in claim 2 wherein the polymer is an ethylene vinyl acetate (EVA) polymer.

4. The composite building board as described in claim 2 wherein the polymer is an ethylene acrylic acid (EAA) polymer.

5. The composite building board as described in claim 2 wherein the polymer is thermosetting.

6. The composite building board as described in claim 2 wherein the polymer is thermoplastic.

7. The composite building board as described in claim 2 wherein the polymer coating and boundary layer cross-link to form a polymer chain having a high molecular weight.

8. The composite building board as described in claim 2 wherein the polymer coating cools to form an exterior board surface with a hardness of between 50 to 150 on the Rockwell R Hardness scale.

9. The composite building board described in claim 2 wherein the polymer coating has a thickness of between 0.01 to 500 mils.

10. The composite building board described in claim 2 wherein the mat is formed from non-woven, randomly aligned glass fibers held together by a resin binder.

11. The composite building board as described in claim wherein the porous mat includes a thermoplastic coating.

12. The composite building board as described in claim wherein the polymer coating is a hot melt thermoplastic with a melting point of between approximately 100°

F. to 500°

F.

13. A composite building board comprising:

at least one cementitious slurry layer having an external surface, wherein the cementitious layer is enhanced by way of a polymer;

a thermoplastic coating chemically bound to the cementitious layer, whereby a polymer matrix is formed within the composite building board.

14. The composite building board as described in claim 13 wherein the cementitious slurry layer is formed from gypsum.

15. The composite building board as described in claim 14 wherein the cementitious slurry layer includes a polymer additive.

16. The composite building board as described in claim 15 wherein a fibrous mat is embedded within the cementitious slurry layer.

17. The composite building board as described in claim 16 wherein the fibrous mat is held together by a resin binder and wherein the fibrous mat is included in the polymer matrix.

18. The composite building board as described in claim 13 wherein an intervening layer is positioned between the slurry layer and the thermoplastic coating.

19. The composite building board as described in claim 13 wherein the thermoplastic coating is a holt met thermoplastic with a melting point of between approximately 100°

F. to 500°

F.

20. The composite building board as described in claim 16 wherein a thermoplastic pre-coating is applied to the fibrous mat.

21. The composite building board as described in claim 13 wherein the board includes a paper face.

22. A composite structural panel comprising:

a slurry layer with an embedded mat, the mat consisting essentially of fibers that are bound together by a hot melt thermoplastic.

23. The composite structural panel as described in claim 22 wherein the fibers are organic.

24. The composite structural panel as described in claim 22 wherein the fibers are inorganic.

25. The composite structural panel as described in claim 22 wherein the fibers are continuous.

26. The composite structural panel as described in claim 22 wherein the fibers are non continuous.

27. The composite structural panel as described in claim 22 wherein the hot melt thermoplastic is applied in a layer that follows the topography of the underlying mat.

28. The composite structural panel as described in claim 22 wherein the hot melt thermoplastic is applied in a smooth layer.

29. The composite structural panel as described in claim 22 wherein the hot melt thermoplastic is applied in a layer having a thickness of between 0.1 to 10 mils.

30. The composite structural panel as described in claim 22 wherein the hot melt thermoplastic is formed from ethylene vinyl acetate (EVA).

31. The composite structural panel as described in claim 22 wherein the hot melt thermoplastic is formed from ethylene methyl acrylonitrile (EAA).

32. The composite structural panel as described in claim 22 wherein the hot melt thermoplastic is translucent.

33. The composite structural panel as described in claim 22 wherein the hot melt thermoplastic is colored.

34. A composite structural panel comprising:

first and second gypsum slurry layers, wherein the second slurry layer has a higher density than the first layer;

a porous mat comprising a series of individual fibers held together by a hot melt thermoplastic binder, the mat embedded within second slurry layer, whereby an exterior surface of the mat is substantially covered with gypsum slurry, thereby creating a gypsum boundary layer;

a surface layer of hot melt thermoplastic overlying the boundary layer;

a silane coupling agent that facilitates bonding between the individual fibers, the individual fibers and the thermoplastic binder, the individual fibers and the first and second slurry layers, the surface layer and the boundary layer, and the surface layer and the first and second slurry layers.