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US 12,006,685 B2Granted
Wallboard with foam material layer
AssigneeGold Bond Building Products, LLC
InventorsBradley J. Busche, Joseph J. Bailey, Brian G. Randall, Michael N. Blades
Life of this patent
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Abstract
Provided are wallboard panels that include a foam material layer and a core material, with one or more sheets of facer material and/or one or more sheets of backing material. The foam material layer may include one or more pores having an open pore geometry. Additionally, provided are methods of manufacturing such wallboard panels.
Claims18
A wallboard panel, comprising:
- a cementitious core material, wherein the cementitious core material comprises gypsum core material;
- one or more sheets of facing material comprising a first polymer foam material layer, the first polymer foam material layer comprising a first plurality of pores having an open pore geometry, the first plurality of pores being randomly distributed, wherein the cementitious core material penetrates the first plurality of pores of the first polymer foam material layer, wherein the cementitious core material does not penetrate through the full thickness of the first polymer foam material layer;
- and
- one or more sheets of backing material comprising a second polymer foam material layer, the second polymer foam material layer comprising a second plurality of pores having an open pore geometry, the second plurality of pores being randomly distributed, wherein the cementitious core material penetrates the second plurality of pores of the second polymer foam material layer, wherein the cementitious core material does not penetrate through the full thickness of the second polymer foam material layer;
- wherein the cementitious core material is between the one or more sheets of facing material and the one or more sheets of backing material.
2 more elements
A wallboard panel, comprising:
- a cementitious core material, wherein the cementitious core material comprises gypsum core material;
- one or more sheets of facing material comprising a first polymer foam material layer, the first polymer foam material layer comprising a first plurality of pores having an open pore geometry, the first plurality of pores being randomly distributed, wherein the cementitious core material penetrates the first plurality of pores of the first polymer foam material layer, the cementitious core material penetrating the first plurality of pores of the first polymer foam material layer at a depth of 5% or more of a thickness of the first polymer foam material layer, wherein the penetration of the first plurality of pores of the first polymer foam material layer by the cementitious core material secures the first polymer foam material layer to the cementitious core material;
- and
- one or more sheets of backing material comprising a second polymer foam material layer, the second polymer foam material layer comprising a second plurality of pores having an open pore geometry, the second plurality of pores being randomly distributed, wherein the cementitious core material penetrates the second plurality of pores of the second polymer foam material layer, the cementitious core material penetrating the second plurality of pores of the second polymer foam material layer at a depth of 5% or more of a thickness of the second polymer foam material layer, wherein the penetration of the second plurality of pores of the second polymer foam material layer by the cementitious core material secures the second polymer foam material layer to the cementitious core material;
- wherein the cementitious core material is between the one or more sheets of facing material and the one or more sheets of backing material.
2 more elements
Dependencies are inferred from the claim text.