Plastic Coated Composite Building Boards and Method of Making Same
AssigneeCertainTeed Gypsum, Inc.
InventorsRobert J. Hauber, Gerald D. Boydston
Life of this patent
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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:
- a slurry layer with an embedded mat, the mat consisting essentially of fibers that are bound together by a hot melt thermoplastic.
A composite structural panel comprising:
- first and second gypsum slurry layers, wherein the second slurry layer has a higher density than the first layer;
- a porous mat comprising a series of individual fibers held together by a hot melt thermoplastic binder, the mat embedded within second slurry layer, whereby an exterior surface of the mat is substantially covered with gypsum slurry, thereby creating a gypsum boundary layer;
- a surface layer of hot melt thermoplastic overlying the boundary layer;
- a silane coupling agent that facilitates bonding between the individual fibers, the individual fibers and the thermoplastic binder, the individual fibers and the first and second slurry layers, the surface layer and the boundary layer, and the surface layer and the first and second slurry layers.
A method for constructing a composite structural panel in a continuous manufacturing process, the method comprising:
- providing a porous mat having interior and exterior surfaces;
- penetrating the porous mat with a dense cementitious slurry layer to substantially cover the exterior surface;
- forming a boundary layer with the slurry, the boundary layer substantially covering the exterior surface of the porous mat;
- delivering a core slurry layer onto the interior surface of the porous mat;
- adhering a thermoplastic coating in a molten state to the boundary layer.
Dependencies are inferred from the claim text.