Plural extruder method for making a composite building panel
First Claim
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1. A method for making a glass fiber reinforced building panel comprising:
- (a) extruding a molten polymer compound to form a molten first web comprising an outer layer and an inner layer wherein at least said outer layer contains a pigment, said outer layer containing more pigment than said inner layer;
(b) extruding a molten polymer compound to form a molten second web spaced from said first web;
(c) positioning a glass fiber mat between said first web and said second web so that said inner layer is adjacent said mat and said outer layer is spaced from said mat;
(d) pressing the first and second webs and said mat together before said webs have completely solidified so that said first web and second web each extend into said glass fiber mat and join to form a composite panel comprising a topcoat layer and a basecoat layer; and
(e) cooling said composite panel to form a building panel.
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Abstract
A glass fiber reinforced building panel is made by extruding molten first and second webs of polymer compounds through spaced die openings, positioned a glass fiber mat between the first and second webs, pressing the webs and mat together, and cooling to form a building panel. The building panel of the invention has improved fire retardance and better field cutting and sawing performance compared with conventional, unreinforced building panels.
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Citations
21 Claims
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1. A method for making a glass fiber reinforced building panel comprising:
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(a) extruding a molten polymer compound to form a molten first web comprising an outer layer and an inner layer wherein at least said outer layer contains a pigment, said outer layer containing more pigment than said inner layer; (b) extruding a molten polymer compound to form a molten second web spaced from said first web; (c) positioning a glass fiber mat between said first web and said second web so that said inner layer is adjacent said mat and said outer layer is spaced from said mat; (d) pressing the first and second webs and said mat together before said webs have completely solidified so that said first web and second web each extend into said glass fiber mat and join to form a composite panel comprising a topcoat layer and a basecoat layer; and (e) cooling said composite panel to form a building panel. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A method for making a fiber reinforced polymer panel comprising:
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extruding a substantially flat molten first web of polymer material, said first web comprising an outer layer and an inner layer wherein at least said outer layer, contains a pigment, said outer layer containing more pigment than said inner layer; extruding a substantially flat molten second web of polymer material spaced from and substantially parallel with said first web; positioning a fiber mat between and substantially parallel with, said first web and said second web so that said inner layer is adjacent said mat and said outer layer is spaced from said mat; pressing said first and second webs and said mat together while said webs are molten to flow polymer material through said mat and join said webs and said mat into a substantially flat composite panel; and cooling said composite panel. - View Dependent Claims (16, 17)
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18. A method for making a glass fiber reinforced polymer panel comprising:
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extruding a first substantially flat molten first web of polymer material from a first extrusion die, said first web comprising an outer layer and an inner layer wherein at least said outer layer contains a pigment, said outer layer containing more pigment than said inner layer; extruding a second substantially flat molten second web of polymer material from a second extrusion die; positioning a glass fiber mat between said first web and said second web so that said inner layer is adjacent said mat and said outer layer is spaced from said mat; moving said molten webs and a glass fiber mat substantially continuously through a roll nip with said webs on opposite sides of said mat to press said molten webs together and against said mat therebetween wherein said roll nip includes a resiliently compressible material and the webs are pressed together under a sufficient force to flow polymer material through said mat and join the webs and the mat together into a flat composite panel with minimal wrinkling. - View Dependent Claims (19, 20, 21)
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Specification