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US 2017/0284093 A1Published application
Building board and method of forming the building board
AssigneeCertainTeed Gypsum, Inc.
InventorsChoung-Houng LAI, Gerald BOYDSTON, Bryan WILTZIUS, Nathan FRAILEY, Michael J. LEMBERGER
Life of this patent
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Abstract
A building board including a cementitious layer between two fiber mats. At least one fiber mat forms with a polymer film a fiber mat/polymer film laminate. The cementitious layer of the building board contains a reactive water-insoluble polymer which improves binding of the fiber mat/polymer film laminate to the cementitious layer. The building board has a low water absorption and a high level surface finish.
Claims20
A building board comprising:
- a cementitious layer between a first fiber mat and a second fiber mat, the first fiber mat and the second fiber mat being at least partially embedded in the cementitious layer, the first fiber mat having a first surface and a second surface opposite the first surface, and the second fiber mat is closer to the first surface than to the second surface;
- a first adhesive layer directly attached to the second surface of the first fiber mat;
- and
- a first polymer film attached to an outer surface of the first adhesive layer, wherein the cementitious layer comprises a reactive water-insoluble polymer adapted for binding the first fiber mat and the second fiber mat to the cementitious layer.
1 more element
A method of manufacturing a building board, comprising:
- preparing a laminate comprising a polymer film attached by an adhesive layer to a first fiber mat, the laminate comprising a mat surface and a polymer surface;
- applying a cementitious slurry onto the mat surface of the laminate;
- applying a second mat onto the cementitious slurry;
- and
- drying the cementitious slurry to form a cementitious layer,
- wherein the building board has a water absorption of not greater than 10% by weight after 2-hour immersion as per ASTM C 473-13, and wherein the cementitious slurry comprises a reactive water-insoluble polymer adapted for binding the first mat and the second mat to the cementitious layer.
3 more elements
Dependencies are inferred from the claim text.