Plastic coated composite building boards and method of making same

• US 8,486,516 B2
• Filed: 06/08/2009
• Issued: 07/16/2013
• Est. Priority Date: 08/29/2008
• Status: Active Grant

• Current Assignee: Certainteed Gypsum Incorporated (Compagnie De Saint-Gobain)
• Original Assignee: Certainteed Gypsum Incorporated (Compagnie De Saint-Gobain)
• Inventors: Boydston, Gerald D., Hauber, Robert J.
• Primary Examiner(s): Sample, David
• Assistant Examiner(s): KHAN, TAHSEEN
• Application Number:
  US12/480,159
• Publication Number:
  US 20100055431A1
• Time in Patent Office: 1,499 Days
• Field of Search: 428/218, 428/306.6, 428/411.1, 428/457, 428/537.5, 442/59, 442/172, 442/331
• US Class Current: 428/218
• CPC Class Codes: B28B 19/0092 to webs, sheets or the like, e.g. of paper, cardboard
• CPC Class Codes: B28B 23/0006 the reinforcement consisting of aligned, non-metal reinforcing elements
• CPC Class Codes: B29D 99/0021 provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix
• CPC Class Codes: B32B 13/04 comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a glass layer B32B17/06
• CPC Class Codes: B32B 13/08 of paper or cardboard
• CPC Class Codes: B32B 13/12 of synthetic resin
• CPC Class Codes: B32B 13/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2250/44 Number of layers variable across the laminate
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary 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 2262/101 Glass fibres
• CPC Class Codes: B32B 2264/10 Inorganic particles
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/402 Coloured
• CPC Class Codes: B32B 2307/414 : Translucent
• CPC Class Codes: B32B 2307/50 : having particular mechanical properties
• CPC Class Codes: B32B 2307/514 : Oriented
• CPC Class Codes: B32B 2307/536 : Hardness
• CPC Class Codes: B32B 2307/54 : Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/554 : Wear resistance
• CPC Class Codes: B32B 2307/558 : Impact strength, toughness
• CPC Class Codes: B32B 2307/58 : Cuttability
• CPC Class Codes: B32B 2307/5825 : Tear resistant
• CPC Class Codes: B32B 2307/71 : Resistive to light or to UV
• CPC Class Codes: B32B 2307/7265 : Non-permeable
• CPC Class Codes: B32B 2419/00 : Buildings or parts thereof
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/10 : of paper or cardboard
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/28 : comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
• CPC Class Codes: B32B 27/30 : comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/306 : comprising vinyl acetate or vinyl alcohol (co)polymers
• CPC Class Codes: B32B 27/308 : comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 3/04 : characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• 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: B32B 7/10 : at least one layer having inter-reactive properties
• CPC Class Codes: C04B 14/42 : Glass
• CPC Class Codes: C04B 2111/00405 : Materials with a gradually increasing or decreasing concentration of ingredients or property from one layer to another
• CPC Class Codes: C04B 2111/00612 : as one or more layers of a layered structure
• CPC Class Codes: C04B 24/2623 : Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 24/2682 : Halogen containing polymers, e.g. PVC
• CPC Class Codes: C04B 24/42 : Organo-silicon compounds
• CPC Class Codes: C04B 28/14 : containing calcium sulfate cements gypsum-paper plates E04C
• CPC Class Codes: E04C 2/043 : of plaster E04C2/049 takes precedence
• CPC Class Codes: E04C 2/06 : reinforced
• CPC Class Codes: Y10T 428/24992 : Density or compression of components
• CPC Class Codes: Y10T 428/249955 : Void-containing component partially impregnated with adjacent component
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31678 : Of metal
• CPC Class Codes: Y10T 428/31993 : Of paper
• CPC Class Codes: Y10T 442/20 : Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
• CPC Class Codes: Y10T 442/2926 : Coated or impregnated inorganic fiber fabric
• CPC Class Codes: Y10T 442/604 : Strand or fiber material is glass

Abstract

Disclosed are composite building boards and associated manufacturing methods. The composite boards may include, for example, one or more slurry layers with embedded fibrous mats. An exterior plastic coating is mechanically adhered to the underlying slurry layer. The plastic layer chemically bonds and cross-links with polymer additives within the slurry layer. The result is an integrated polymer matrix with greatly improved durability and surface strength.

Claims

1. A composite building board comprising:

upper and lower mats formed from non-woven, randomly aligned glass fibers held together by a binder, the mats being porous and having interior and exterior surfaces;

a hot melt thermoplastic pre-coating with a melting point between approximately 100°

F. to 500°

F., the pre-coating applied to the randomly aligned glass fibers of the upper and lower mats, the pre-coating leaving gaps between the individual fibers to allow for the passage of a slurry;

upper and lower dense slurry layers coating and penetrating the upper and lower mats and the corresponding thermoplastic pre-coating, whereby the exterior surface of each mat is substantially covered by slurry, a slurry boundary layer defined by the slurry covering the exterior surface of each mat, the boundary layer having a thickness of between approximately 0.01 to 2.0 mm, the upper and lower dense slurry layers including a polymeric additive that increases the strength of the composite board and that bonds with the thermoplastic pre-coating;

a core slurry layer extending between and bonded to the upper and lower dense slurry layers, the core slurry layer having a density that is less than the density of the upper and lower dense slurry layers, the core slurry layer including a polymeric additive that bonds with the polymeric additive of the upper and lower slurry layers and the thermoplastic pre-coating;

a non-curing hot melt thermoplastic coating uniformly applied in a molten state to the slurry boundary layer at a temperature of between approximately 100°

to 500°

F., the non-curing hot melt thermoplastic coating mechanically adhering to the slurry boundary layer upon cooling, the thermoplastic coating also crosslinking with the polymeric additive of the upper, lower and core slurry layers and the thermoplastic pre-coating to form a composite polymer matrix, the thermoplastic coating having a thickness of between 0.01 to 500 mils.

2. The composite building board as described in claim 1 wherein the non-curing thermoplastic pre-coating comprises ethylene vinyl acetate (EVA).

3. The composite building board as described in claim 1 wherein the thermoplastic pre-coating has a thickness of approximately 0.1 to 10 mils.

4. The composite building board as described in claim 1 wherein the upper and lower mats are treated with a silane coupling agent prior to the pre-coating being applied.

5. A composite building board comprising:

upper and lower mats formed from non-woven, randomly aligned glass fibers held together by a binder, the mats being porous and having interior and exterior surfaces;

a hot melt thermoplastic pre-coating with a melting point between approximately 100°

F. to 500°

F., the pre-coating applied to the randomly aligned glass fibers of the upper and lower mats, the pre-coating leaving gaps between the individual fibers to allow for the passage of a slurry;

upper and lower dense slurry layers coating and penetrating the upper and lower mats and the corresponding thermoplastic pre-coating, whereby the exterior surface of each mat is substantially covered by slurry, a slurry boundary layer defined by the slurry covering the exterior surface of each mat, the boundary layer having a thickness of between approximately 0.01 to 2.0 mm, the upper and lower dense slurry layers including a polymeric additive that increases the strength of the composite board and that bonds with the thermoplastic pre-coating;

a core slurry layer extending between and bonded to the upper and lower dense slurry layers, the core slurry layer having a density that is less than the density of the upper and lower dense slurry layers, the core slurry layer including a polymeric additive that bonds with the polymeric additive of the upper and lower slurry layers and the thermoplastic pre-coating;

a non-curing hot melt thermoplastic coating comprising ethylene methyl acrylonitrile (EMA) and having a melting point between 100°

to 500°

F. mechanically adhered to the slurry boundary layer, the non-curing thermoplastic coating also crosslinking with the polymeric additive of the upper, lower and core slurry layers and the thermoplastic pre-coating to form a composite polymer matrix, the non-curing thermoplastic coating having a thickness of between 0.01 to 500 mils.

6. A composite, multi-layered building panel comprising:

coplanar opposed upper and lower mats formed from non-woven, randomly aligned inorganic fibers held together by a binder, the mats being porous and each having an interior essentially planar surface proximate the opposed mat and an essentially exterior planar surface distal from the opposed mat;

upper and lower dense slurry layers providing a coating and penetrating the upper and lower mats, whereby the exterior surface of each essentially planar mat is substantially covered by slurry, a slurry boundary layer defined by the slurry covering the exterior essentially planar surface of each mat, the boundary layer having a thickness of between approximately 0.01 to 2.0 mm, each of the upper and lower dense slurry layers including a polymeric additive;

a core slurry layer extending between and bonded to the upper and lower dense slurry layers, the core slurry layer having a density that is less than the density of the upper and lower dense slurry layers;

a hot melt non-curing thermoplastic coating disposed adjacent the slurry boundary layer of at least one of the boundary layers, the hot melt non-curing thermoplastic coating having a melting point temperature of between approximately 100°

to 500°

F., and when cooled, the hot melt non-curing thermoplastic coating mechanically adhering to the slurry boundary layer and being chemically bonded to the thermoplastic by cross-linking thereof with the polymeric additive of the upper, lower and core slurry layers to form a composite polymer matrix, the thermoplastic coating having a thickness of between 0.01 to 500 mils.

7. The composite, multi-layered building panel according to claim 6 wherein the core slurry layer further comprises at least a sufficient amount of polymeric additive to enable the core slurry layer to chemically bond with the polymeric additive contained in the upper and lower slurry layers.

8. The composite, multi-layered building panel according to claim 6 further comprising a hot melt thermoplastic pre-coating with a melting point between approximately 100°

F. to 500°

F., the pre-coating disposed on the randomly aligned inorganic fibers of at least one of the upper and lower mats, the pre-coating leaving interstitial gaps between the individual randomly aligned inorganic fibers to allow for the passage of a slurry through the gaps.

9. The composite, multi-layered building panel according to claim 6 wherein the hot melt thermoplastic coating further comprises a filler material.

10. The composite, multi-layered building panel according to claim 8 wherein the core slurry layer further includes a polymeric additive that bonds with the polymeric additive of the upper and lower slurry layers and with the polymeric additive pre-coating.

11. The composite, multi-layered building panel according to claim 8 wherein the thermoplastic pre-coating has a thickness of approximately 0.1 to 10 mils.

12. The composite, multi-layered building panel according to claim 8 wherein at least one of the upper and lower mats are treated with a silane coupling agent prior to the pre-coating being applied.

13. The composite, multi-layered building panel according to claim 9 wherein the hot melt thermoplastic coating filler material further comprises micro gas bubbles.