Plastic coated composite building boards and method of making same

• US 9,259,888 B2
• Filed: 07/15/2013
• Issued: 02/16/2016
• 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: Hauber, Robert J., Boydston, Gerald D.
• Primary Examiner(s): KHAN, TAHSEEN
• Application Number:
  US13/941,950
• Publication Number:
  US 20130295286A1
• Time in Patent Office: 946 Days
• Field of Search: 428/218, 442/394, 427/299
• US Class Current: 1/1
• 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 layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• 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 walls, panels B32B2607/00
• 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 method of manufacturing a composite, multi-layered building panel in a continuous production line process, the method comprising:

providing non-woven, randomly aligned inorganic fibers;

forming upper and lower mats by applying a binder to bind the randomly aligned inorganic fibers to each other, the upper and lower mats being porous and having interior and exterior surfaces defined by their orientation in the building panel;

coating the upper and lower mats by applying upper and lower dense cementitious slurry layers so that the exterior surface of each mat is substantially covered by dense cementitious slurry and thereby forming a slurry boundary layer defined by the dense cementitious 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 cementitious slurry layers including a polymeric additive entrained therein that increases the strength of the composite building panel;

delivering a core slurry layer, having a density less than the density of the upper and lower dense slurry layers, onto the lower mat and dense slurry layer in an amount to provide for a predetermined thickness of the core slurry layer;

applying the upper mat, including the dense slurry layer and the entrained additive, onto the core slurry layer, whereby the core slurry layer extends between and is bonded to the upper and lower dense layers;

forming the surfaces of the upper and lower mats to produce the building panel having a predetermined thickness so that the slurry boundary layers are each disposed on an exterior surface of the mats;

before the core slurry layer of the building panel completely sets, and prior to the panel passing through associated dryers, uniformly applying onto the slurry boundary layer of at least one of the upper and lower mat and dense slurry combinations a non-curing hot melt thermoplastic coating in a molten state at a temperature of between approximately 100°

to 500°

F. to a thickness of between 0.01 to 500 mils, the non-curing hot melt thermoplastic coating mechanically adhering to the at least one slurry boundary layer upon cooling, the thermoplastic coating cross-linking with the polymeric additive of the at least one upper and lower dense slurry layers to thereby form a composite polymer matrix.

2. The method of manufacture for making a composite, multi-layered building panel according to claim 1 further comprising:

after the forming of the upper and lower mats, applying 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.

3. A method for the continuous manufacture of a composite, multi-layered building panel comprising, the method comprising the following steps:

providing upper and lower mats formed from non-woven, randomly aligned inorganic fibers that are held together with a binder, the upper and lower mats having interior and exterior surfaces defined by their orientation in the building panel;

coating the upper and lower mats by applying upper and lower dense cementitious slurry layers so that the exterior surface of each mat is substantially covered by dense cementitious slurry and thereby forming a slurry boundary layer defined by the dense cementitious slurry covering the exterior surface of each mat;

delivering a core slurry layer, having a density less than the density of the upper and lower dense slurry layers, onto the lower mat and dense slurry layer in an amount to provide for a predetermined thickness of the core slurry layer;

applying the upper mat, including the dense slurry layer onto the core slurry layer, whereby the core slurry layer extends between and is bonded to the upper and lower dense layers;

before the curing of the core slurry layer, upper dense slurry layer, or lower dense slurry layer, uniformly applying onto the slurry boundary layer of at least one of the upper and lower mat and dense slurry combinations a non-curing hot melt thermoplastic coating in a molten state.

4. The method as described in claim 3 wherein the hot melt thermoplastic coating is applied at a thickness of between 0.01 to 500 mils.

5. The method as described in claim 3 wherein the hot melt thermoplastic coating is mechanically adhered to the at least one slurry boundary layer upon cooling.

6. The method as described in claim 3 wherein the hot melt thermoplastic coating is applied at a temperature of between approximately 100°

F. to approximately 500°

F.

7. The method as described in claim 3 comprising the further step forming the surfaces of the upper and lower mats to produce the building panel having a predetermined thickness so that the slurry boundary layers are each disposed on an exterior surface of the mats.

8. The method as described in claim 3 wherein the non-curing hot melt thermoplastic coating is an ethylene acrylic acid (EAA) polymer.

9. The method as described in claim 3 wherein the non-curing hot melt thermoplastic coating is an ethylene vinyl acetate (EVA) polymer.

10. The method as described in claim 3 comprising the further step of cooling the thermoplastic coating to form an exterior board surface with a hardness of between 50 to 150 on the Rockwell R Hardness scale.

11. The method as described in claim 3 wherein the hot melt thermoplastic is translucent.

12. The method as described in claim 3 wherein the hot melt thermoplastic is colored.

13. The method as described in claim 3 wherein the slurry boundary layer is applied at a thickness of between approximately 0.01 to 2.0 mm.

14. The method of manufacture for making a composite, multi-layered building panel according to claim 3 further comprising:

after the forming of the upper and lower mats, applying 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.

15. The method as described in claim 3 comprising the further step of adding a polymeric additive to the upper and lower dense slurry layers to increase the strength of the composite building panel.

16. The method as described in claim 15 comprising the further step of cross-linking the non-curing thermoplastic coating with the polymeric additive of the at least one upper and lower slurry layers to thereby form a composite polymer matrix.

17. A method for constructing a composite building board in a continuous manufacturing process, the method comprising:

providing a porous mat having interior and exterior surfaces;

penetrating the porous mat with a dense cementitious slurry layer to substantially cover the exterior surface;

forming a boundary layer with the slurry, the boundary layer substantially covering the exterior surface of the porous mat;

delivering a core slurry layer onto the interior surface of the porous mat;

before the slurry of the building board sets, forming a polymer matrix within the composite building board by adhering a non-curing thermoplastic coating in a molten state to the boundary layer.