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US 10,767,368 B2Granted
Plastic coated composite building boards and method of making same
AssigneeCertainTeed Gypsum, Inc.
InventorsRobert J. Hauber, Gerald D. Boydston
Life of this patent
Estimating the term…
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.
Claims20
A composite structural panel comprising:
- an exterior gypsum layer;
- a mat embedded within the exterior gypsum layer, the mat consisting essentially of fibers that are bound together by a hot melt thermoplastic binder and are not bound together by any thermoset binder, the mat having an exterior surface and an interior surface, wherein the mat is porous and the exterior gypsum layer penetrates through pores of the mat from the interior surface to the exterior surface thereof, and forms an exterior boundary sublayer substantially covering the exterior surface of the mat and an interior boundary sublayer substantially covering the interior surface of the mat;
- an interior gypsum layer formed in contact with the interior boundary sublayer of the exterior gypsum layer, wherein the interior gypsum layer has a lower density than the exterior gypsum slurry layer.
A composite structural panel comprising:
- an exterior gypsum layer;
- a mat embedded within the exterior gypsum layer, the mat consisting essentially of fibers that are bound together by a polymeric binder that consists essentially of a hot melt thermoplastic, the mat having an exterior surface and an interior surface, wherein the mat is porous and the exterior gypsum layer penetrates through pores of the mat from the interior surface to the exterior surface thereof, and forms an exterior boundary sublayer substantially covering the exterior surface of the mat and an interior boundary sublayer substantially covering the interior surface of the mat;
- an interior gypsum layer formed in contact with the interior boundary sublayer of the exterior gypsum layer, wherein the interior gypsum layer has a lower density than the exterior gypsum slurry layer.
A composite structural panel comprising:
- an exterior gypsum layer;
- a mat embedded within the exterior gypsum layer, the mat consisting essentially of fibers that are bound together entirely by a hot melt thermoplastic binder, the mat having an exterior surface and an interior surface, wherein the mat is porous and the exterior gypsum layer penetrates through pores of the mat from the interior surface to the exterior surface thereof, and forms an exterior boundary sublayer substantially covering the exterior surface of the mat and an interior boundary sublayer substantially covering the interior surface of the mat;
- an interior gypsum layer formed in contact with the interior boundary sublayer of the exterior gypsum layer, wherein the interior gypsum layer has a lower density than the exterior gypsum slurry layer.
Dependencies are inferred from the claim text.