Plastic coated composite building boards and method of making same

• US 9,885,179 B2
• Filed: 02/16/2016
• Issued: 02/06/2018
• 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:
  US15/044,639
• Publication Number:
  US 20160273220A1
• Time in Patent Office: 721 Days
• Field of Search: None
• 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 for constructing a composite structural panel 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;

adhering a molten coating, the majority of which comprises a non-curing thermoplastic polymer, over the boundary layer.

2. The method as described in claim 1 wherein the thermoplastic coating forms a polymer matrix with the composite structural panel.

3. The method as described in claim 1 wherein the thermoplastic coating is applied prior to the curing of the boundary layer.

4. The method as described in claim 1 wherein the thermoplastic coating is applied after the curing of the boundary layer.

5. The method as described in claim 1 wherein the thermoplastic coating is applied prior to the curing of the core.

6. The method as described in claim 1 wherein the thermoplastic coating is applied after the curing of the core.