Polyester laminated building boards with improved surface characteristics
AssigneeSaint-Gobain Placo
InventorsGerald D. Boydston, Bryan J. Wiltzius, Choung-Houng Lai, Michael J. Lemberger
Life of this patent
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Abstract
This disclosure relates to using polyester films on building boards to enable improved surface coatings. The polyester film is preferably applied to a glass mat via an adhesive to form a laminate. This laminate is then bonded to the exterior surface of a gypsum board. The polyester film is advantageous because it allows for exterior surface coatings to be applied. In one embodiment, an exterior acrylic coating is applied to the polyester film. Boards constructed in accordance with this disclosure allow for exterior finishings to be achieved without the need for excessive finishing materials or steps.
Claims26
A method for making a building panel comprising:
- a first mat having an interior and an exterior surface;
- a set gypsum core bonded to the interior surface of the first mat;
- a polymer film having an interior and an exterior surface;
- and
- an adhesive adhering the interior surface of the polymer film to the exterior surface of the first mat, the adhesive including an outer stratum substantially free of the material that makes up the first mat, the outer stratum having a smooth outer face adhering the interior surface of the polymer film to the exterior surface of the first mat,
- the method comprising:
- providing a laminate comprising the first mat and the polymer film, the interior surface of the polymer film being adhered to the exterior surface of the first mat by the adhesive;
- and
- forming the set gypsum core against the interior surface of the first mat, such that the set gypsum core bonds to the interior surface of the first mat.
A method for making a building panel comprising:
- a laminate comprising a perforated polymer film bound to a sheet;
- a core of set gypsum;
- the laminate disposed against the set gypsum core;
- a polymer coating over an exterior surface of the perforated polymer film, the polymer coating providing a surface finish to the building panel;
- and
- an adhesive adhering the perforated polymer film to the sheet, the adhesive including a smooth outer stratum being substantially free of the material that makes up the sheet,
- the method comprising
- providing the laminate comprising the perforated polymer film bound to the sheet;
- and
- forming the core of set gypsum against the sheet of the laminate.
A building panel comprising:
- a first mat having an interior and an exterior surface;
- a set gypsum core bonded to the interior surface of the first mat;
- a polymer film having an interior and an exterior surface;
- and
- an adhesive adhering the interior surface of the polymer film to the exterior surface of the first mat, the adhesive including an outer stratum substantially free of the material that makes up the first mat, the outer stratum having an outer face adhering the interior surface of the polymer film to the exterior surface of the first mat, wherein the outer stratum is smooth.
Dependencies are inferred from the claim text.