# US 12,006,685 B2 · Wallboard with foam material layer

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- Number: US 12,006,685 B2
- Document ID: US12006685B2
- Status: Granted
- Kind: B2
- Application number: 17/118,835
- Filed: 2020-12-11
- Published: 2021-06-17
- Granted: 2024-06-11
- Earliest claimed: 2019-12-12
- Assignees: Gold Bond Building Products, LLC
- Applicants: National Gypsum Properties, LLC
- Inventors: Bradley J. Busche; Joseph J. Bailey; Brian G. Randall; Michael N. Blades
- Web page: https://patentgrep.com/patent/US12006685B2

## CPC

- E04C 2/288: composed of insulating material and concrete, stone or stone-like material
- B32B 5/022: {Non-woven fabric}
- B32B 5/024: {Woven fabric}
- B32B 5/028: {Net structure, e.g. spaced apart filaments bonded at the crossing points}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 5/30: one layer {being formed of particles, e.g. chips,} granules, powder
- B32B 5/32: {at least two} layers being foamed {and next to each other}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 9/005: {comprising one layer of ceramic material, e.g. porcelain, ceramic tile (layered products with at least two ceramic layers composed mainly of ceramic B32B18/00)}
- B32B 9/046: {of foam}
- B32B 9/06: of paper or cardboard
- 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)}
- B32B 13/045: {of foam}
- B32B 13/08: of paper or cardboard
- B32B 13/12: of synthetic resin
- B32B 13/14: next to a fibrous or filamentary layer
- B32B 19/04: next to another layer of {the same or of} a {different material (next to a glass layer B32B17/067)}
- B32B 19/045: {of synthetic resin}
- B32B 19/046: {of paper or cardboard}
- B32B 19/047: {of foam}
- B32B 19/06: next to a fibrous or filamentary layer
- B32B 27/065: {of foam}
- B32B 27/08: of synthetic resin
- B32B 27/10: of paper or cardboard
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/22: using plasticisers
- B32B 29/005: {next to another layer of paper or cardboard layer}
- B32B 29/007: {next to a foam layer}
- B32B 29/02: next to a fibrous or filamentary layer
- B32B 2250/03: 3 layers
- B32B 2250/05: 5 or more layers
- B32B 2255/02: on fibrous or filamentary layer
- B32B 2255/06: on metal layer
- B32B 2255/10: on synthetic resin layer or on natural or synthetic rubber layer
- B32B 2255/102: synthetic resin or rubber layer being a foamed layer
- B32B 2255/12: on paper layer
- B32B 2255/28: Multiple coating on one surface
- B32B 2262/062: Cellulose fibres, e.g. cotton
- B32B 2262/10: Inorganic fibres
- B32B 2262/101: Glass fibres
- B32B 2264/067: Wood particles
- B32B 2264/102: Oxide or hydroxide
- B32B 2264/104: Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
- B32B 2266/02: Organic
- B32B 2266/0207: Materials belonging to B32B25/00
- B32B 2266/0214: Materials belonging to B32B27/00
- B32B 2266/0221: Vinyl resin
- B32B 2266/0228: Aromatic vinyl resin, e.g. styrenic (co)polymers
- B32B 2266/0235: Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
- B32B 2266/025: Polyolefin
- B32B 2266/0264: Polyester
- B32B 2266/0278: Polyurethane
- B32B 2266/0285: Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
- B32B 2266/06: Open cell foam
- B32B 2266/08: Closed cell foam
- B32B 2307/102: Insulating
- B32B 2307/302: Conductive
- B32B 2307/306: Resistant to heat
- B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant
- B32B 2307/50: having particular mechanical properties
- B32B 2307/536: Hardness
- B32B 2307/558: Impact strength, toughness
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/72: Density
- B32B 2307/724: Permeability to gases, adsorption
- B32B 2307/726: Permeability to liquids, absorption
- B32B 2307/732: Dimensional properties
- B32B 2419/00: Buildings or parts thereof
- B32B 2607/00: Walls, panels
- E04B 1/90: slab-shaped
- E04B 1/942: {slab-shaped}
- E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001})

## 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.

## Claims

### Claim 1

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.

### Claim 2 (depends on 1)

The wallboard panel of claim 1, wherein at least 0.01% to about 100% of the first plurality of pores comprises an open pore geometry.

### Claim 3 (depends on 1)

The wallboard panel of claim 1, wherein the first polymer foam material layer has a thickness ranging from about 0.01 mm to about 50 mm.

### Claim 4 (depends on 1)

The wallboard panel of claim 1, wherein the first polymer foam material layer has a thickness ranging from about 6 mm to about 10 mm.

### Claim 5 (depends on 1)

The wallboard panel of claim 1, wherein the first polymer foam material layer comprises a polyurethane.

### Claim 6 (depends on 1)

The wallboard panel of claim 1, wherein the first polymer foam material layer comprises a reticulated ester-based polyurethane.

### Claim 7 (depends on 1)

The wallboard panel of claim 1, wherein the first polymer foam material layer comprises an ether-based polyurethane.

### Claim 8 (depends on 1)

The wallboard panel of claim 1, wherein the first polymer foam material layer comprises an impregnated polyurethane.

### Claim 9 (depends on 1)

The wallboard panel of claim 1, wherein the first polymer foam material layer comprises a polyester.

### Claim 10 (depends on 1)

The wallboard panel of claim 1, wherein the first polymer foam material layer comprises a reticulated polyester.

### Claim 11 (depends on 1)

The wallboard panel of claim 1, wherein the first polymer foam material layer comprises melamine.

### Claim 12 (depends on 1)

The wallboard panel of claim 1, wherein the one or more sheets of backing material further comprise one or more sheets of paper.

### Claim 13 (depends on 1)

The wallboard panel of claim 1, wherein the one or more sheets of facing material further comprise a filler material.

### Claim 14 (depends on 1)

The wallboard panel of claim 1, wherein the panel has a thermal conductivity of from 0.03 W/m*K to 0.5 W/m*K, a thermal resistance of from 0.03 K*m2/W to 0.3 K*m2/W, and/or an R-value of from 0.4 to 5.

### Claim 15 (depends on 1)

The wallboard panel of claim 1, wherein the panel has a soft body impact resistance of from 200 J to 500 J and/or a hard body impact resistance of from 100 J to 300 J.

### Claim 16 (depends on 1)

The wallboard panel of claim 1, wherein the cementitious core material primarily contains gypsum.

### Claim 17

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.

### Claim 18 (depends on 17)

The wallboard panel of claim 17, wherein the cementitious core material primarily contains gypsum.