Methods for manufacturing cementitious reinforced panels
OwnerTheodore E. Clearinventor
Life of this patent
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Abstract
Reinforced facings, including reinforcing webs entrained in hydraulic cement via a slurry bath, adhere to a nailable lightweight aggregate cementitious core to form a panel web. The reinforced web is formed on abutting conveyed carrier sheets, and the web is transversely cut, between the sheets, while moving or when stopped, in response to sensing of the sheets. The cut panels, on respective sheets are stacked for curing without damaging the panel edges and in a manner to minimize panel flex. Slurry bath, facing applicators, and cutter and stacking apparatus are included.
Claims32
A method for manufacturing cementitious panels of the type having a nailable cementitious aggregate core faced on each major side with a reinforcing element bathed in a slurry comprising hydraulic cement, the method comprising the steps of:
- running an elongated indefinite length web of pervious reinforcing material through a slurry bath and depositing an amount of slurry thereto to form a first wet uncured flexible cementitious element;
- depositing cementitious aggregate core material on said uncured flexible cementitious element;
- running a second elongated indefinite length web of pervious reinforcing material through a second slurry bath, and depositing an amount of slurry thereto to form a second wet uncured flexible cementitious element;
- laying the second element on said core material;
- thereby adhering the elements to respective major sides of said aggregate core material to form an uncured panel web;
- thereafter cutting said uncured panel web to form separate uncured cementitious panels;
- and thereafter curing said panels.
A method for manufacturing cementitious panels of the type having a nailable cementitious aggregate core faced on each major side with a reinforcing element bathed in a slurry comprising hydraulic cement, the method comprising the steps of:
- running an elongated indefinite length web of pervious reinforcing material through a slurry bath, and metering the amount of slurry adhering thereto to form a first uncured flexible web of reinforcement material;
- laying the first uncured reinforcement material indefinite length web on a plurality of abutted, moving carrier sheets;
- depositing cementitious aggregate core material on said web;
- compacting said core material;
- running a second elongated indefinite length web of pervious reinforcing material through a second slurry bath, and metering the amount of slurry adhering thereto to form a second uncured flexible web of reinforcement material;
- laying the second uncured reinforcing material indefinite length web on said compacted core material;
- thereby adhering the reinforcing webs to respective major sides of said aggregate core material to form an uncured panel web;
- thereafter cutting said uncured panel web to form separate cementitious panels, by drawing a knife across said uncured panel web from one edge thereof to another and between said carrier sheets while said uncured panel web lies on said sheets;
- and thereafter curing said panels.
A method for manufacturing cementitious panels of the type having a nailable cementitious aggregate core faced on each major side with a reinforcement element bathed in a slurry comprising hydraulic cement, the method comprising the steps of:
- forming an elongated uncured panel web, comprising said core and said reinforcing elements, on moving abutting carrier sheets;
- thereafter cutting said uncured web to form separate cementitious panels, one on each carrier sheet, by cutting said web transversely between said sheets;
- and thereafter curing said panels.
A method for manufacturing cementitious panels of the type having a nailable cementitious core faced on each major side with a reinforcing element bathed in a slurry comprising hydraulic cement, the method comprising the steps of:
- running a first elongated indefinite length web of reinforcing material through a slurry bath and depositing said slurry thereto to form a first uncured flexible cementitious element;
- metering the amount of slurry deposited on said first web;
- dragging an upper surface of said web against a bar to force slurry into said web, while leaving slurry on said upper surface;
- depositing cementitious aggregate core material on said uncured flexible cementitious element;
- running a second elongated indefinite length web of reinforcing material through a second slurry bath, and depositing slurry thereto to form a second uncured flexible cementitious element;
- metering the amount of slurry deposited on said first web;
- dragging an upper surface of said web against a bar to force slurry into said web, while leaving slurry on said upper surface;
- laying the second element on said core material;
- thereby adhering the elements to respective major sides of said aggregate core material to form an uncured panel web;
- and thereafter curing said panel.
A method for manufacturing cementitious panels of the type having a nailable cementitious no slump aggregate core faced on each major side with a reinforcing element bathed in a slurry comprising hydraulic cement, the method comprising the steps of:
- running an elongated indefinite web of pervious reinforcing mesh material through a slurry bath and depositing an amount of slurry thereto to form a first wet uncured flexible cementitious element;
- depositing cementitious no slump aggregate core material on said uncured flexible cementitious element;
- running a second elongated indefinite length web of pervious reinforcing mesh material through a second slurry bath, and depositing an amount of slurry thereto to form a second wet, uncured flexible cementitious element;
- said slurry residing on both sides of said first and second webs and within interstices of said mesh material;
- laying the second element on said core material;
- adhering by the bonding of said slurry the elements to respective major sides of said aggregate core material to form an uncured panel web;
- thereafter cutting said uncured panel web to form separate uncured cementitious panels;
- and thereafter curing said panels.
Dependencies are inferred from the claim text.