System and Method for Constructing Composite Building Boards Using Thermoplastic Films
First Claim
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 interior and exterior surfaces;
applying a hot melt thermoplastic coating to the exterior surface of the first mat by way of a curtain coater, the curtain coater being in-line with 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 pre-coating to a first 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 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.
1 Assignment
0 Petitions
Accused Products
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.
7 Citations
30 Claims
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1. A method of manufacturing glass reinforced composite building boards, the method being carried out on a series of forming tables, the method comprising:
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dispensing a length of a first mat comprising a plurality of non-woven, randomly aligned glass fibers, the first mat having interior and exterior surfaces; applying a hot melt thermoplastic coating to the exterior surface of the first mat by way of a curtain coater, the curtain coater being in-line with 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 pre-coating to a first 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 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. - View Dependent Claims (29, 30)
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2. A method of manufacturing glass building boards comprising:
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dispensing a length of a first mat, the first mat having interior and exterior surfaces; applying a thermoplastic coating to the exterior surface of the first mat; allowing the applied thermoplastic coating to partially cool; 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. - View Dependent Claims (3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A system for manufacturing building boards along a production line, the system comprising:
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a roll of a first glass mat, the first mat having interior and exterior surfaces; a coating apparatus and a supply of a hot melt thermoplastic, the coating apparatus being used to apply a thin layer of the hot melt thermoplastic on the exterior surface of the first glass mat; guide rollers for inverting the first glass mat after the application of the hot melt thermoplastic, the guide rollers allowing the applied thermoplastic coating to partially cool; a series of forming tables positioned downstream of the coating apparatus, the guide rollers 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. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23)
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24. A system for manufacturing building boards, the system utilizing a forming table and a mixer for supplying a slurry, the system further comprising:
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a roll of a mat, the mat having interior and exterior surfaces; a coating apparatus positioned in-line with the forming table and the mixer, the coating apparatus containing a supply of a thermoplastic and functioning to supply a layer of the thermoplastic on the exterior surface of the mat. - View Dependent Claims (25, 26, 27, 28)
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Specification