Composite facer for wallboards
AssigneeMilliken & Company
InventorsRobert M. Smith, George C. McLarty, III, Andrew D. Child, Samuel E. Graham, W. Randolph Hursey
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Abstract
A composite facer material for use with cementitious wallboards, where the composite facer is embedded in a top and bottom face thereof. The composite facer material, in a most preferred embodiment, comprises two layers. The first layer is preferably a carded polyester nonwoven mat, which is bonded to a second layer comprising preferably a tri-directional laid scrim fabric reinforcement layer made of continuous glass fibers. The two layers are preferably bonded together using an acrylic adhesive, which offers superior adhesion between the layers as well as superior adhesion between the composite facing material and the cementitious core.
Claims34
A wallboard comprising:
- an integral matrix of set cementitious material extending from one face of the board to the other face of the board;
- and
- a composite material including a carded nonwoven mat and a reinforcing fabric layer bonded together, wherein said cementitious material extends over an outer face of said composite material.
A method for manufacturing wallboard, said method comprising the steps of:
- bonding a carded nonwoven mat to a reinforcing fabric layer to form a composite material;
- providing an aqueous cementitious slurry, and bringing said composite material into contact with said slurry;
- and
- allowing said cementitious slurry to flow through and penetrate said composite material to form a continuous film extending over an outer face of said composite material.
A paperless wallboard comprising:
- an integral matrix of set cementitious material extending from one face of the board to the other taco of the board;
- and
- a composite material including a carded nonwoven mat and a reinforcing fabric layer bonded together, wherein said cementitious material extends over an outer face of said composite material.
Dependencies are inferred from the claim text.