BUILDING PRODUCTS CONSTRUCTED FROM THERMOPLASTIC POLYMER MAT IMPREGNATED WTIH CEMENTITIOUS MATERIAL

• US 20110086214A1
• Filed: 10/09/2009
• Published: 04/14/2011
• Est. Priority Date: 10/09/2009
• Status: Abandoned Application

• Current Assignee: Owens Corning Intellectual Capital, LLC (Owens Corning)
• Original Assignee: Owens Corning Intellectual Capital, LLC (Owens Corning)
• Inventors: Rockwell, Anthony L.
• Application Number:
  US12/576,446
• Publication Number:
  US 20110086214A1
• Time in Patent Office: Days
• US Class Current: 428/294.7
• CPC Class Codes: B28B 19/0092 to webs, sheets or the like, e.g. of paper, cardboard
• CPC Class Codes: B32B 13/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 17/02 in the form of fibres or filaments
• CPC Class Codes: B32B 17/04 bonded with or embedded in a plastic substance
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• 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 2262/0253 Polyolefin fibres
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/04 Cellulosic plastic fibres, e.g. rayon
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/14 Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2305/08 Reinforcements
• CPC Class Codes: B32B 2305/20 in the form of a non-woven mat
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2315/06 Concrete
• CPC Class Codes: B32B 2315/18 : Plaster
• CPC Class Codes: B32B 2419/00 : Buildings or parts thereof
• CPC Class Codes: B32B 2419/06 : Roofs, roof membranes
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/18 : characterised by the use of special additives
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/38 : comprising epoxy resins
• CPC Class Codes: B32B 3/266 : characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 38/08 : Impregnating
• CPC Class Codes: B32B 38/164 : Drying
• CPC Class Codes: B32B 5/08 : the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• 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: E04C 2/26 : composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups of cement and mineral fibres E04C2/04
• CPC Class Codes: E04F 13/16 : of fibres or chips, e.g. bonded with synthetic resins , or with an outer layer of fibres or chips E04F13/0864 takes precedence
• 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 428/266 : of base or substrate
• CPC Class Codes: Y10T 428/31551 : Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31601 : Quartz or glass
• CPC Class Codes: Y10T 428/31645 : Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31649 : Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31855 : Of addition polymer from unsaturated monomers

Abstract

A building product includes a thermoplastic polymer mat impregnated with a cementitious material. The thermoplastic polymer mat has a front face and a rear face. A stiffening layer is laminated to the rear face of the thermoplastic polymer mat. A finishing layer covers the front face of the thermoplastic polymer mat. A method of producing the building product is also provided.

Claims

1. A building product, comprising:

a thermoplastic polymer mat impregnated with a cementitious material, said thermoplastic polymer mat having a front face and a rear face;

a stiffening layer laminated to said rear face of said thermoplastic polymer mat; and

a finishing layer covering said front face of said thermoplastic polymer mat.

2. The product of claim 1, wherein said thermoplastic polymer mat is impregnated with said cementitious material through greater than 50% of the thickness of said thermoplastic polymer mat.

3. The product of claim 2, wherein said thermoplastic polymer mat is made from a material selected from a group consisting of polyester, polyethylene, polypropylene, polyethylene terephthalate, polybutylene terephthalate, rayon, nylon and mixtures thereof.

4. The product of claim 3, wherein said cementitious material is selected from a group consisting of concrete, gypsum, plaster, plaster of paris, an elastomeric slurry, a latex, an epoxy, a plastic, spray polypropylene, spray polyurethane and mixtures thereof.

5. The product of claim 4, wherein said stiffening layer is selected from a group of materials consisting of a fiberglass mat, a polyester mat, a PET/glass combination mat, a perforated solid mat made from polypropylene, a perforated polymer film and combinations thereof, treated with a material selected from a group consisting of concrete, gypsum, plaster, plaster of paris, an elastomeric slurry, a latex, an epoxy, a plastic, a spray polypropylene, a spray polyurethane and mixtures thereof prior to laminating to said impregnated thermoplastic polymer mat.

6. The product of claim 5, wherein said finishing layer is made from a material selected from a group consisting of a veil, glass roving, strips of veil, concrete, gypsum, plaster, plaster of paris, an elastomeric slurry, a latex, an epoxy, a plastic, a spray polypropylene, a spray polyurethane, a paint and mixtures thereof.

7. The product of claim 1 wherein said thermoplastic polymer mat comprises multiple layers of thermoplastic polymer mat material.

8. The product of claim 1 wherein said stiffening layer comprises multiple layers of stiffening material.

9. The product of claim 1 wherein said thermoplastic polymer mat prior to impregnation, has a thickness of between about 0.25 to about 4.0 inches, a density of between about 0.6 to about 4.0 pounds per cubic foot, said thermoplastic polymer mat further including an open weave structure to allow penetration of cementitious material to coat fibers in said mat, said thermoplastic polymer mat returning to at least 70% of its original thickness after impregnation.

10. The product of claim 1 wherein said thermoplastic polymer mat further includes reinforcement fibers.

11. The product of claim 10, wherein said reinforcement fibers are selected from a group consisting of thermoplastic fibers, a continuous strand of thermoplastic fibers, poltruded thermoplastic fibers, chopped glass fibers, a continuous strand of glass fibers, poltruded glass fibers, and mixtures thereof.

12. The product of claim 11, wherein said chopped thermoplastic reinforcement fibers have a length of between about 0.5 to about 2.0 inches, a diameter of between about 9 to about 100 microns and are selected from a material consisting of PET, nylon, polypropylene and mixtures thereof.

13. The product of claim 11, wherein said chopped glass fibers have a length of between about 0.5 to about 2.0 inches and a diameter of between about 6 and about 25 microns.

14. The product of claim 1, wherein said thermoplastic polymer mat is impregnated with said cementitious material through greater than 60% of the thickness of said thermoplastic polymer mat.

15. The product of claim 1, wherein said thermoplastic polymer mat is impregnated with said cementitious material through greater than 70% of the thickness of said thermoplastic polymer mat.

16. The product of claim 1, wherein said thermoplastic polymer mat is impregnated with said cementitious material through greater than 80% of the thickness of said thermoplastic polymer mat.

17. The product of claim 1, wherein said thermoplastic polymer mat is impregnated with said cementitious material through greater than 90% of the thickness of said thermoplastic polymer mat.

18. The product of claim 1, wherein said thermoplastic polymer mat is impregnated with said cementitious material through about 100% of the thickness of said thermoplastic polymer mat.

19. A method of producing a building product, comprising:

impregnating said thermoplastic polymer mat with a cementitious material;

drying said impregnated thermoplastic polymer mat;

stiffening said impregnated thermoplastic polymer mat by adding a stiffening layer to a rear face of said impregnated thermoplastic polymer mat;

adding a finishing layer over said front face of said impregnated thermoplastic polymer mat; and

drying said finishing layer.

20. The method of claim 19, including molding at least a front face of a thermoplastic polymer mat into a desired shape prior to impregnating.

21. The method of claim 19, including using a thermoplastic polymer mat made from a material selected from a group consisting of polyester, polyethylene, polypropylene, polyethylene terephthalate, polybutylene terephthalate, rayon, nylon and mixtures thereof alone or in combination with reinforcement fibers.

22. The method of claim 21, including using a cementitious material selected from a group consisting of concrete, gypsum, plaster, plaster of paris, an elastomeric slurry, a latex, an epoxy, a plastic, spray polypropylene, spray polyurethane and mixtures thereof.

23. The method of claim 19, including using a cementitious material selected from a group consisting of concrete, gypsum, plaster, plaster of paris, an elastomeric slurry, a latex, an epoxy, a plastic, spray polypropylene, spray polyurethane and mixtures thereof.

24. The method of claim 19, wherein said impregnating step includes coating said thermoplastic polymer mat with said cementitious material and then compressing said coated thermoplastic polymer mat so as to force cementitious material through greater than 50% of the thickness of said coated thermoplastic polymer mat.

25. The method of claim 24, wherein said compressing is performed by using pressure rollers.

26. The method of claim 24, further including selecting said stiffening layer from a group of materials consisting of a fiberglass mat, a polyester mat, a PET/glass combination mat, a perforated solid mat made from polypropylene, a perforated polymer film and combinations thereof.

27. The method of claim 26, including treating said stiffening layer with a material selected from a group consisting of concrete, gypsum, plaster, plaster of paris, an elastomeric slurry, a latex, an epoxy, a plastic, a spray polypropylene, a spray polyurethane and mixtures thereof prior to laminating to said impregnated thermoplastic polymer mat.

28. The method of claim 24, further including using a material selected from a group consisting of a woven mat, veil, glass roving, strips of veil, concrete, gypsum, plaster, plaster of paris, an elastomeric slurry, a latex, an epoxy, a plastic, a spray polypropylene, a spray polyurethane, a paint and mixtures thereof as said finishing layer.

29. The method of claim 19, including drying using a hot air oven, chemical catalysts and combinations thereof.

30. The method of claim 19, further including using a fiberglass mat for said stiffening layer.

31. The method of claim 30, including treating said fiberglass mat with a material selected from a group consisting of gypsum, plaster, plaster of paris, an elastomeric slurry, a latex, an epoxy, a plastic, a spray polypropylene, a spray polyurethane and mixtures thereof prior to laminating to said impregnated thermoplastic polymer mat.

32. The method of claim 19, further including using a material selected from a group consisting of a veil, glass roving, strips of veil, concrete, gypsum, plaster, plaster of paris, an elastomeric slurry, a latex, an epoxy, a plastic, a spray polypropylene, a spray polyurethane, a paint and mixtures thereof as said finishing layer.

33. The method of claim 19, wherein said thermoplastic polymer mat is a continuous web and completing said molding, impregnating, drying, stiffening, adding and drying steps in-line in a continuous manufacturing process.

34. The method of claim 33, including cutting said product to a desired length.

35. The method of claim 19, including also molding a rear face of said thermoplastic polymer mat before impregnating.