Cementitious exterior sheathing product with rigid support member

• US 7,861,476 B2
• Filed: 09/19/2005
• Issued: 01/04/2011
• Est. Priority Date: 11/05/2002
• Status: Expired due to Term

• 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): Glessner; Brian E
• Assistant Examiner(s): Cajilig; Christine T
• Application Number:
  US11/229,913
• Publication Number:
  US 20060010800A1
• Time in Patent Office: 1,933 Days
• Field of Search: 522/55, 522/56, 522/871, 522/881, 524/49, 524/54, 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. An exterior sheathing product comprising:

a board of fiber cement material attached to a first wall and a second wall of a support member;

the support member having a first nailing flange and fastener receiving holes through the first nailing flange;

the support member having a second nailing flange and further fastener receiving holes through the second nailing flange, wherein the first wall and the second wall are between the first nailing flange and the second nailing flange, and wherein the board is attached to and covers the first wall and the second wall, while the fastener receiving holes and the further fastener receiving holes are uncovered by the board to receive fasteners;

a cementitious bond promoter disposed on an exterior-facing side of said support member;

the board of fiber cement material including a multilayered sheet; and

an interlaminar bond strength promoter for adhesion between layers of the multilayered sheet.

2. The exterior sheathing product of claim 1, comprising:

a shape cut into the board to provide a desired appearance.

3. The exterior sheathing product of claim 1, comprising:

the first wall and the second wall being perforated with through-holes mechanically locking with the fiber cement material.

4. The exterior sheathing product of claim 1, comprising:

the first wall and the second wall being perforated with through-holes mechanically locking with the fiber cement material; and

prongs adjacent to the through-holes, wherein the prongs are imbedded in the board.

5. The exterior sheathing product of claim 1, comprising:

the first wall and the second wall comprising a mesh or scrim mechanically locking with the fiber-cement material.

6. The exterior sheathing product of claim 5 wherein,

the further fastener receiving holes are uncovered by the board to receive fasteners without development of cracks or over-stressed areas in the board.

7. The exterior sheathing product of claim 5, comprising:

a shape cut into the board to provide a desired appearance.

8. The exterior sheathing product of claim 5, comprising:

the first wall and the second wall being perforated with through-holes mechanically locking with the fiber cement material.

9. The exterior sheathing product of claim 5, comprising:

the first wall and the second wall being perforated with through-holes mechanically locking with the fiber cement material; and

prongs adjacent to the through-holes, wherein the prongs are imbedded in the board.

10. The exterior sheathing product of claim 5 wherein the fiber cement material comprises a multi-layered sheet.

11. The exterior sheathing product of claim 5, comprising:

a third wall between the first wall and the first flange, and

a fourth wall between the second wall and the second flange.

12. The exterior sheathing product of claim 1 wherein the fiber cement material comprises a multi-layered sheet.

13. The exterior sheathing product of claim 1, comprising:

a third wall between the first wall and the first flange, and

a fourth wall between the second wall and the second flange.