Asymmetrical concrete backerboard and method for making same
OwnerJeffrey Dinkelinventor
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Abstract
The present invention is a backerboard having a fiberglass mesh on one side, and a impervious reinforcement membrane on the other side. The backerboard incorporates a low density, high compressive strength concrete core having an upper principal surface and a lower principal surface. The upper principal surface of the core is covered by a fiberglass mesh reinforcement layer, itself covered and bonded to the core by a thin layer of Portland cement. The lower principal surface of the backerboard is covered with a high tensile strength, impervious reinforcement membrane.
Claims35
A construction element for use as an underlayment or backerboard comprising:
- (a) a core having an upper principal surface and a lower principal surface;
- and
- (b) an impervious membrane on the lower principal surface of the core;
- the core including alkaline resistant fibers.
A construction element for use as an underlayment or backerboard comprising:
- (a) a core having an upper principal surface and a lower principal surface;
- (b) a pervious upper reinforcement material on the upper principal surface of the core;
- (c) an upper coating in communication with the upper principal surface of the core and the pervious upper reinforcement material;
- and
- (d) an impervious membrane on the lower principal surface of the core.
A construction element for use as an underlayment or backerboard comprising:
- (a) a cement core having an upper principal surface and a lower principal surface;
- (b) a pervious reinforcement layer on the upper principal surface of the core;
- (c) a cement slurry binding the reinforcement layer to the upper principal surface of the core;
- and
- (d) a high tensile strength, impervious moisture barrier membrane bound to the lower principal surface of the core.
A method of manufacturing a construction element for use as an underlayment or backerboard comprising the following steps:
- (a) conveying a sheet of impervious reinforced membrane through a core station;
- and
- (b) depositing at the core station a core material on the impervious reinforced membrane;
- the core material including alkaline resistant fibers;
- the impervious reinforced membrane acting as a carrier sheet.
A method of manufacturing a construction element for use as an underlayment or backerboard comprising the following steps:
- (a) conveying a sheet of impervious reinforced membrane through a core station;
- (b) depositing at the core station a core material on the impervious reinforced membrane;
- and
- (c) layering a pervious membrane atop the core material such that the core material is sandwiched between the pervious membrane and the impervious membrane
- the impervious reinforced membrane acting as a carrier sheet throughout the manufacturing process.
A method of manufacturing a construction element for use as an underlayment or backerboard comprising the following steps:
- (a) conveying a sheet of impervious reinforced membrane through the steps of the method of manufacturing;
- (b) depositing a core material from a core material hopper to the conveyed impervious reinforced membrane;
- and
- (c) screeding the core material on the conveyed sheet of impervious reinforced membrane with a screed;
- (d) compacting the core material on the conveyed sheet of impervious reinforced membrane with a compactor;
- (e) bathing a conveyed pervious reinforced membrane through a bath of cement;
- and
- (f) layering the pervious reinforced membrane on the core material on the conveyed sheet of impervious reinforced membrane;
- and
- (g) cutting the manufactured construction element into panels.
Dependencies are inferred from the claim text.