Cementitious exterior sheathing product with rigid support member

• US 7,028,436 B2
• Filed: 11/05/2002
• Issued: 04/18/2006
• Est. Priority Date: 11/05/2002
• Status: Expired due to Fees

• Current Assignee: Plycem USA, Inc. (Elementia SAB de CV)
• Original Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Inventors: Bezubic, William Paul Jr.
• Primary Examiner(s): Friedman, Carl D.
• Assistant Examiner(s): HORTON, YVONNE MICHELE
• Application Number:
  US10/288,189
• Publication Number:
  US 20040118076A1
• Time in Patent Office: 1,260 Days
• Field of Search: 522/871, 522/881, 527/170.1, 527/180.4, 527/180.5, 527/180.2, 527/170.4
• US Class Current: 52/288.1
• CPC Class Codes: B28B 1/526 by delivering the materials on a conveyor of the endless-belt type
• CPC Class Codes: B28B 1/527 by delivering the materials on a rotating drum, e.g. a sieve drum, from which the materials are picked up by a felt
• CPC Class Codes: B28B 7/46 for humidifying or dehumidifying
• CPC Class Codes: B32B 13/02 with fibres or particles being present as additives in the layer
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 18/24 Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper , cork
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/00637 as glue or binder for uniting building or structural materials
• CPC Class Codes: C04B 24/24 Macromolecular compounds C04B24/14 takes precedence; macromolecular compounds comprising sulfonate or sulfate groups C04B24/16
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: C04B 40/006 involving the elimination of excess water from the mixture
• CPC Class Codes: C04B 40/0071 making use of a rise in pressure
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4578 Coating or impregnating of green ceramics or unset concrete
• CPC Class Codes: C04B 41/483 Polyacrylates
• CPC Class Codes: C04B 41/5076 with masses bonded by inorganic cements sulfur compositions C04B41/5097
• CPC Class Codes: C04B 41/63 Macromolecular compounds
• CPC Class Codes: E04C 2/04 : of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibresE04C2/26 takes precedence; material or manufacture B28, C04
• CPC Class Codes: E04F 13/141 : with an outer layer of concrete E04F13/147 takes precedence
• 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: E04F 15/10 : of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard , or with a top layer of other materials
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

Cementitious exterior sheathing products are provided which include a rigid support member affixed to a cementitious layer. The rigid support member includes at least one nailing flange disposed along one of its lateral sides for allowing the sheathing product to be affixed to an exterior wall of a building. Preferred mechanical and adhesive bonding techniques are suggested for combining the cementitious layer and rigid support member together to form an integrated product. Such products are lighter in weight and are more crack resistant than currently available fiber cement trim boards.

Claims

1. A fiber cement trim board comprising:

(a) an elongated rigid support member having a wall-facing side and an exterior-facing side, a pair of lateral side portions and a pair of longitudinal ends, said exterior-facing side including at least a first and a second exterior wall portion thereon;

(b) a first nailing flange disposed along at least a first of said pair of lateral side portions;

(c) a fiber cement layer disposed at least on a portion of said exterior-facing side of said rigid support member;

said fiber cement layer exhibiting an aesthetic appearance wherein said rigid support member comprises a cement bond promoter disposed on said exterior-facing side thereof.

2. The fiber cement trim board of claim 1 wherein said cement bond promoter comprises an acrylic-based material.

3. A method of manufacturing fiber cement board, comprising:

(a) forming a rigid support member having a wall-facing side and an exterior-facing side, a pair of lateral sides and a pair of longitudinal ends, said forming step producing at least first and second exterior wall portions;

(b) disposing a fiber cement layer on a portion of said exterior-facing side of said rigid support member, said fiber cement layer exhibiting an aesthetic appearance wherein said disposing step (b) comprises layering said fiber cement layer onto said exterior-facing side of said rigid support member, followed by permitting said fiber cement layer to set.

4. A fiber cement board manufactured by the method of claim 3.

5. A fiber cement trim board comprising:

(a) an elongated rigid support member comprising galvanized steel, said rigid support member having a wall-facing side and an exterior-facing side, said exterior facing side of said rigid support member including first and second pairs of generally parallel walls forming a rectangular enclosure having a longitudinal slotted opening;

(b) a pair of nail flanges extending from the walls of said rectangular enclosure proximate to said longitudinal slotted opening, said nail flanges having a plurality of fastener receiving holes disposed therethrough, said rigid support member also including a plurality of through-holes distributed among said pair of parallel walls; and

(c) a fiber cement layer disposed on a portion of said exterior-facing side of said rigid support member, said fiber cement layer being also disposed through at least a portion of said plurality of through-holes in said pair of parallel walls for forming a mechanical locking engagement with said rigid support member.

6. The fiber cement trim board of claim 5 wherein said rigid support member comprises galvanized steel lath or galvanized and perforated steel sheet or plate.

7. The fiber cement trim board of claim 5 further comprising a resinous cement bond promoter disposed on said exterior-facing side to assist in bonding said fiber cement layer to said rigid support member.

8. The fiber cement trim board of claim 5 wherein said fiber cement layer comprises cellulosic fiber, silica sand and portland cement.

9. A cementitious exterior sheathing product comprising:

(a) a rigid metal support member having a wall-facing side and an exterior-facing side, a pair of lateral sides and a pair of longitudinal ends, said rigid support member including a nail flange disposed along one of its lateral sides;

(b) a cementitious layer disposed at least on a portion of said exterior-facing side of said rigid support member, said cementitious layer exhibiting an aesthetic appearance wherein said exterior-facing side of said metal support member comprises a cement bond promoter.

10. A cementitious exterior sheathing product comprising:

(a) a rigid metal support member having a wall-facing side and an exterior-facing side, a pair of lateral sides and a pair of longitudinal ends, said rigid support member including a nail flange disposed along one of its lateral sides;

(b) a cementitious layer disposed at least on a portion of said exterior-facing side of said rigid support member, said cementitious layer exhibiting an aesthetic appearance wherein said metal support member is at least partially embedded within said cementitious layer.