Laminated foam composite backer board for wet space construction
AssigneeMGNT Products Group LLC
InventorsPeter Nielsen, William M. DeJesus
Life of this patent
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Abstract
A composite backer board for wet space construction is disclosed, along with a method of producing the backer board. The board includes a rigid foam core of a suitable thickness for wet space construction. A first fabric layer is fixed to at least one face of the rigid foam core with a polymeric adhesive. A first polymer layer is on the first fabric layer in which the polymer layer is dimensionally stable parallel to the face of the rigid foam core. A second fabric layer is on the first polymer layer opposite the first fabric layer and forms a first face that is amenable to thin set mortar and related compositions in wet space construction.
Claims25
A composite backer board for wet space construction, said board comprising:
- a rigid foam core of a suitable thickness for wet space construction;
- a first fabric layer fixed to at least one face of said rigid foam core with a polymeric adhesive;
- a first polymer layer on said first fabric layer in which the polymer layer is dimensionally stable parallel to said face of said rigid foam core;
- and
- a second fabric layer on said first polymer layer opposite said first fabric layer and forming a first face that is amenable to thin set mortar and related compositions in wet space construction.
A composite backer board for wet space construction, said board comprising:
- a rigid foam core of a suitable thickness for wet space construction;
- a first facer layer fixed to one face of said rigid foam core with a polymeric adhesive;
- and
- a second facer layer fixed to one face of said rigid foam core opposite said first facer layer with a polymeric adhesive.
A method of making a composite board that is particularly suited for thin set mortar and wet space construction, the method comprising:
- feeding two fabric layers with a melted polymer there between to a pair of nip rollers to join the fabric layers and the melted polymer;
- and
- curing the melted polymer between the two fabric layers to produce a dimensionally stable composite facer structure.
A method of bonding a dimensionally stable polymeric film with little to no mechanical bonding sites to polymer foam, the method comprising:
- fixing a fabric layer to said dimensionally stable polymeric film with a polymeric adhesive or resin;
- and
- fixing said fabric layer to said polymer foam with said polymeric adhesive or resin opposite said dimensionally stable polymeric film.
Dependencies are inferred from the claim text.