Method of manufacturing composite board

#The present invention concerns a method of manufacturing composite board whereby a continuous coat of mortar reinforced with glass cloth or a similar material is laid onto a continuous core.

#The Austrian Patent No. 242,581 discloses a method of manufacturing composite boards with cores of expanded material. The cores are positioned and introduced horizontal and coated with soft mortar. The mortar is compacted with a pivoting cylinder. Downstream of the cylinder glass cloth is removed from a roll, forced down against the top of the mortar, and entrained by the advancing web. Farther downstream another coating of mortar is applied loosely to the first coating and the glass cloth and compacted with another pivoting cylinder.

#The two coats of plastic over the expanded-material core of a composite manufactured by the method disclosed in the Austrian Patent No. 242,581 are together much thicker than their framing. They are heavy and inappropriate for such interior structures as tiled walls. Such composites are accordingly primarily employed on flat roofs and facades. In other words, much more mortar is used to embed and attach the glass cloth than is needed for interior construction.

#For a full understanding of the present invention, reference should now be made to the following detailed description of the preferred embodiments of the invention as illustrated in the accompanying drawings.

#FIG. 1a illustrates a production line for manufacturing a continuous core.

#FIG. 1b illustrates another version of a production line for manufacturing a continuous core.

#The creation of a continuous core 2 will now be discussed with reference to FIG. 1a. An extruder 31 extrudes a layer of expanding extrudate 21 onto a roller pavement 30. A fiber distributer 32 deposits staple or wadding 22 or 22' onto the advancing expanding extrudate 21. The staple or wadding can be mineral or plastic fiber, sheep's, llama's, or other animal wool, fiber from recycled clothing etc. or a combination thereof. Fiber distributer 32 can deposit staple or wadding 22 or 22' onto expanding extrudate 21 loose or tight.

#The core can be a core 2'" with two layers instead of a core 2 with one layer. Core 2'" can comprise a layer of expanding extrudate 21 and a layer of staple or wadding 22 or 22'. Another layer of expanding extrudate 21 can be extruded over staple or wadding 22 or 22', producing a core 2"" in the form of a sandwich with a layer of staple or wadding between two outer layers of expanding extrudate.

#Another type of core is illustrated in FIG. 1b. Mineral or animal staple or wadding 22 or 22' is compressed into a web by a fiber compactor 32'. Upon leaving the compactor, staple or wadding 22 or 22' will be relieved of pressure and expand again, and individual fibers will project out of the upper surface of the core. When an extruder or extruders 31' and 32' extrude expanding extrudate 21 onto this loosely compacted core of staple or wadding 22 or 22', the projecting fibers enter into an intimate bond with the extrudate. The result is a continuous core 2"" that rests on pavement 30' and exhibits the positive properties of a hardened expanding extrudate 21 in conjunction with staple or wadding 22 or 22', specifically satisfactory insulation of noise and heat along with static and dynamic endurance.