Facing material with controlled porosity for construction boards

• US 7,049,251 B2
• Filed: 01/21/2003
• Issued: 05/23/2006
• Est. Priority Date: 01/21/2003
• Status: Expired due to Term

• Current Assignee: Saint-Gobain Adfors Canada Ltd. (Compagnie De Saint-Gobain)
• Original Assignee: Saint-Gobain Technical Fabrics Canada Limited (Compagnie de Saint-Gobain SA)
• Inventors: Porter, John Frederick
• Primary Examiner(s): Morris, Terrel
• Assistant Examiner(s): Salvatore, Lynda
• Application Number:
  US10/348,489
• Publication Number:
  US 20040142618A1
• Time in Patent Office: 1,218 Days
• Field of Search: 442/189, 442/210, 442/225, 442/279, 442/386, 442/355, 442/256, 442/266, 442/86, 442/85, 442/79, 442/118, 442/238, 442/286, 428/903, 428/219, 428/294.7, 428/911, 428/913
• US Class Current: 442/79
• CPC Class Codes: B28B 19/0092 to webs, sheets or the like, e.g. of paper, cardboard
• CPC Class Codes: B32B 17/02 in the form of fibres or filaments
• CPC Class Codes: B32B 3/00 Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 40/02 Selection of the hardening environment
• CPC Class Codes: C04B 41/48 Macromolecular compounds
• CPC Class Codes: D03D 15/00 Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
• CPC Class Codes: D03D 15/41 with specific twist
• CPC Class Codes: D03D 9/00 Open-work fabrics
• CPC Class Codes: D10B 2101/06 Glass
• CPC Class Codes: D10B 2101/08 Ceramic
• CPC Class Codes: D10B 2101/12 Carbon; Pitch
• CPC Class Codes: D10B 2201/24 Viscose
• CPC Class Codes: D10B 2321/021 polyethylene
• CPC Class Codes: D10B 2321/022 polypropylene
• CPC Class Codes: D10B 2321/121 polystyrene
• CPC Class Codes: D10B 2331/021 aromatic polyamides, e.g. aramides
• CPC Class Codes: D10B 2331/04 polyesters, e.g. polyethylene terephthalate [PET]
• CPC Class Codes: D10B 2401/063 high strength
• CPC Class Codes: D10B 2505/20 : for civil engineering, e.g. geotextiles
• CPC Class Codes: E04C 2/043 : of plaster E04C2/049 takes precedence
• CPC Class Codes: Y10S 428/911 : Penetration resistant layer
• CPC Class Codes: Y10S 428/913 : Material designed to be responsive to temperature, light, moisture
• CPC Class Codes: Y10T 428/24926 : including ceramic, glass, porcelain or quartz layer
• CPC Class Codes: Y10T 428/249946 : Glass fiber
• CPC Class Codes: Y10T 428/249949 : Two or more chemically different fibers
• CPC Class Codes: Y10T 428/249952 : At least one thermosetting synthetic polymeric material layer
• CPC Class Codes: Y10T 442/2164 : Coating or impregnation specified as water repellent
• CPC Class Codes: Y10T 442/2484 : Coating or impregnation is water absorbency-increasing or hydrophilicity-increasing or hydrophilicity-imparting
• CPC Class Codes: Y10T 442/3008 : Woven fabric has an elastic quality
• CPC Class Codes: Y10T 442/3236 : Including inorganic strand material
• CPC Class Codes: Y10T 442/3301 : Coated, impregnated, or autogenous bonded
• CPC Class Codes: Y10T 442/3309 : Woven fabric contains inorganic strand material
• CPC Class Codes: Y10T 442/3317 : Woven fabric contains synthetic polymeric strand material
• CPC Class Codes: Y10T 442/335 : Plural fabric layers
• CPC Class Codes: Y10T 442/3366 : Woven fabric is coated, impregnated, or autogenously bonded
• CPC Class Codes: Y10T 442/3463 : Plural fabric layers
• CPC Class Codes: Y10T 442/3472 : Woven fabric including an additional woven fabric layer
• CPC Class Codes: Y10T 442/348 : Mechanically needled or hydroentangled
• CPC Class Codes: Y10T 442/3496 : Coated, impregnated, or autogenously bonded
• CPC Class Codes: Y10T 442/3594 : Woven fabric layers impregnated with a thermoplastic resin [e.g., vinyl polymer, etc.]
• CPC Class Codes: Y10T 442/361 : At least one layer is derived from water-settable material [e.g., cement, gypsum, etc.]
• CPC Class Codes: Y10T 442/3667 : Composite consisting of at least two woven fabrics bonded by an interposed adhesive layer [but not two woven fabrics bonded together by an impregnation which penetrates through the thickness of at least one of the woven fabric layers]
• CPC Class Codes: Y10T 442/3691 : Fabric layer contains glass strand material
• CPC Class Codes: Y10T 442/3724 : Needled
• CPC Class Codes: Y10T 442/3732 : Including an additional nonwoven fabric
• CPC Class Codes: Y10T 442/3797 : Coating or impregnation is derived from a water-settable material [e.g., cement, gypsum, etc.]
• CPC Class Codes: Y10T 442/60 : Nonwoven fabric [i.e., nonwoven strand or fiber material]
• CPC Class Codes: Y10T 442/604 : Strand or fiber material is glass
• CPC Class Codes: Y10T 442/607 : Strand or fiber material is synthetic polymer
• CPC Class Codes: Y10T 442/652 : Nonwoven fabric is coated, impregnated, or autogenously bonded
• CPC Class Codes: Y10T 442/662 : Needled

Abstract

This invention provides facing materials for cementitious boards such as those including Portland cement or gypsum cores. The preferred facing material includes, in a first embodiment, a facing layer having an areal weight of about 300 grams/M², and an air permeability rating of no greater than about 300 CFM/ft² (FG 436-910 test method). The facing layer reduces the penetration of a slurry of cementitious material during the manufacture of a cementitious board, while permitting the water vapor from the slurry to pass therethrough. The facing materials of this invention can be designed to substantially eliminate the fouling of rolls used in continuous processing of such boards without the use, or with greatly reduced use, of costly viscosity control agents in the slurry. In addition, further embodiments of this invention can include binders, coatings or saturants which are designed to decrease pore size, increase or decrease the contact angle of liquids, or promote greater adhesion to cementitious cores, greater adhesion to other layers in the facing material, or greater adhesion or affinity to various types of adhesive compositions used to join cementitious boards to insulation and exterior finishing systems (EIS or EIFS).

Claims

1. A facing material for use with an aqueous slurry of cementitious material, comprising:

a porous facing layer at an exterior side of the facing material;

the porous facing layer having pores impermeable to liquid water and permeable to water vapor evaporated from said slurry;

the porous facing layer having a first coating or saturant, which reduces porosity of an exterior side of the porous facing layer to resist slurry penetration;

a slurry facing side of the porous facing layer having a second coating or saturant comprising a slurry wetting agent;

a water repellant material on at least an exterior side of the porous facing layer providing the exterior side of the facing material with water repellency to repel rain and water from the facing material, said water repellant material repelling said slurry from penetration through the exterior side of the facing material to prevent slurry contamination on the exterior side of the facing material; and

an inner layer having reinforcing fibers at an interior side of the facing material, the inner layer being substantially porous to said slurry for penetration of said slurry through the inner layer.

2. A facing material for use with an aqueous slurry of cementitious material, comprising:

a porous facing layer at an exterior side of the facing material;

the porous facing layer having pores impermeable to liquid water and permeable to water vapor evaporated from said slurry;

a slurry wetting agent on a slurry facing side of the porous facing layer; and

a hydrophobic agent on the exterior side of the porous facing layer;

said hydrophobic agent comprising, a water repellant material on at least an exterior side of the porous facing layer providing the exterior side of the facing material with water repellency to repel rain and water from the facing material, said water repellant material repelling said slurry from penetration through the exterior side of the facing material to prevent slurry contamination on the exterior side of the facing material; and

an inner layer having reinforcing fibers at an interior side of the facing material, the inner layer being substantially porous to said slurry for penetration of said slurry through the inner layer.

3. The facing material of claim 2, wherein the porous facing layer comprises a mat having fibers, strands, rovings or filaments, or a combination thereof, which are woven, knit, needled, felted or stitched together to decrease porosity of the mat.

4. The facing material of claim 2, further comprising:

the first coating or saturant containing said water repellant material, and further containing, a UV stabilizer, a mold retardant, or a flame retardant, or a combination thereof.

5. The facing material of claim 2, further comprising:

the porous facing layer comprising, fibers bonded by a resinous binder.

6. The facing material of claim 5, wherein the binder further comprises, a UV stabilizer, a mold inhibitor, or a fire retardant, or a combination thereof.

7. The facing material of claim 5, wherein the binder further comprises, a hydrophobic additive to resist slurry penetration.

8. The facing material of claim 2, further comprising:

the inner layer having a material with an affinity for forming an adhesive bond with said slurry.

9. The facing material of claim 2, further comprising:

the porous facing layer comprising, fibers bonded by a resinous binder, wherein the resinous binder further comprises, a carboxylated polymer.

10. The facing material of claim 2, further comprising:

a resin on the inner layer and on a slurry facing side of the porous facing layer, wherein the resin further comprises, a carboxylated polymer.