System and method for constructing composite building boards using thermoplastic films

• US 9,096,036 B2
• Filed: 06/28/2011
• Issued: 08/04/2015
• Est. Priority Date: 06/07/2010
• Status: Active Grant

• Current Assignee: Certainteed Gypsum Incorporated (Compagnie De Saint-Gobain)
• Original Assignee: Certainteed Gypsum Incorporated (Compagnie De Saint-Gobain)
• Inventors: Hauber, Robert Joseph, Boydston, Gerald D.
• Primary Examiner(s): Del Sole, Joseph S
• Assistant Examiner(s): Robitaille, John
• Application Number:
  US13/170,272
• Publication Number:
  US 20110297291A1
• Time in Patent Office: 1,498 Days
• Field of Search: 156/39, 156/44
• US Class Current: 1/1
• CPC Class Codes: B28B 19/0046 to plastics
• 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: 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 13/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2037/1215 Hot-melt adhesive
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/212 Electromagnetic interference shielding
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/536 Hardness
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2307/712 Weather resistant
• CPC Class Codes: B32B 2307/7145 Rot proof, resistant to bacteria, mildew, mould, fungi
• CPC Class Codes: B32B 2307/732 Dimensional properties
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 37/0053 : Constructional details of laminating machines comprising rollers; Constructional features of the rollers
• CPC Class Codes: B32B 37/1207 : Heat-activated adhesive B32B37/04 takes precedence
• CPC Class Codes: B32B 37/14 : characterised by the properties of the layers
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04C 2/043 : of plaster E04C2/049 takes precedence
• CPC Class Codes: E04C 2/246 : combinations of materials fully covered by E04C2/16 and E04C2/20
• CPC Class Codes: E04C 2/28 : combinations of materials fully covered by groups E04C2/04 and E04C2/08

Abstract

Disclosed are building board manufacturing techniques that minimize the build-up of slurry on associated forming equipment and also produce panels with enhanced physical properties. The methods involve applying a dissolvable film laminate to one or more fiber mats at the outset of the forming process. In the un-dissolved state, the film acts as a containment envelope for the gypsum slurry and any free floating glass fibers. During subsequent curing, the film is dissolved by vaporized water. In its dissolved state, the film is liquefied and coats the fibers of the underlying mat. This results in a building board with improved physical properties.

Claims

1. A method of manufacturing glass reinforced composite building boards, the method being carried out on a series of forming tables, the method comprising:

dispensing a length of a first mat comprising a plurality of non-woven, randomly aligned glass fibers, the first mat having an interior and an exterior surface;

applying a hot melt thermoplastic coating to the exterior surface of the first mat by way of a curtain coater, the curtain coater being positioned before the forming tables;

routing the first mat with the applied thermoplastic coating over a guide roller to invert the first mat;

allowing the applied thermoplastic coating to partially cool, whereby the applied thermoplastic coating is adhered to the external surface of the first mat;

delivering the first mat with the adhered thermoplastic coating to a forming table, wherein the adhered thermoplastic coating faces the forming table and the interior surface of the first mat is exposed;

depositing gypsum slurry over the interior surface of the first mat, the deposited gypsum slurry fully penetrating the plurality of glass fibers and coating the exterior surface of the first mat, wherein the deposited gypsum slurry forms a small layer between the exterior surface of the first mat and the partially cooled, adhered thermoplastic coating, and wherein the adhered thermoplastic coating acts as a barrier in limiting the deposited gypsum slurry from contacting the forming tables;

dispensing a length of a second mat comprising a plurality of non-woven, randomly aligned glass fibers over the gypsum slurry, wherein the first mat, the second mat, the gypsum slurry and the thermoplastic coating together form a composite panel;

drying the composite panel via a series of dryers in order to set the gypsum slurry;

cutting the dried composite panel into building boards of a desired length.

2. A method of manufacturing building boards comprising:

dispensing a length of a first mat, the first mat having an interior and an exterior surface;

applying a heated thermoplastic coating to the exterior surface of the first mat;

allowing the applied thermoplastic coating to partially cool and adhere to the first mat;

delivering the first mat with the thermoplastic coating to a forming table, wherein the adhered thermoplastic coating faces the forming table and the interior surface of the first mat is exposed;

depositing a volume of gypsum slurry over the interior surface of the first mat, wherein the deposited gypsum slurry displaces and further cools the partially cooled thermoplastic coating and forms a small layer between the exterior surface of the first mat and the thermoplastic coating.

3. The method as described in claim 2 wherein the first mat comprises a plurality of non-woven, randomly aligned glass fibers.

4. The method as described in claim 2 wherein the thermoplastic coating acts as a barrier in limiting the amount of deposited gypsum slurry that contacts the forming table.

5. The method as described in claim 2 wherein the deposited gypsum slurry is permitted to fully penetrate the first mat.

6. The method as described in claim 2 comprising the further step of dispensing a length of a second mat over the gypsum slurry, wherein the first mat, the second mat, the gypsum slurry and the thermoplastic coating together form a panel.

7. The method as described in claim 6 comprising the further step of drying the panel via a series of dryers in order to dry the deposited gypsum slurry.

8. The method as described in claim 2 comprising the further step of routing the first mat with the applied thermoplastic coating over a guide roller to invert the first mat, whereby the thermoplastic coating is brought into facing relation with the forming table and the interior surface of the first mat is exposed.

9. The method as described in claim 2 wherein the thermoplastic is a molten acrylonitrile butadiene styrene (ABS).

10. The method as described in claim 2 wherein the thermoplastic is a hot melt thermoplastic applied via a curtain coater.