Plasterboards and methods for making them

Patent metadata

Field	Value
Publication number	US-11619044-B2
Application number	US-201816231576-A
Country	US
Kind code	B2
Filing date	Dec 23, 2018
Priority date	Dec 29, 2017
Publication date	Apr 4, 2023
Grant date	Apr 4, 2023

Abstract

An example plasterboard includes a layer of hardened plaster having a first surface and an opposed second surface, a layer of polymer material having particles of one or more cementitiously-active substances mixed therein, and a liner between the first surface of the layer of hardened plaster and the layer of polymer material. Another example is a method of forming such a plasterboard. The method includes loading an extruder with the polymer material having the particles of one or more cementitiously active substances mixed therein, extruding the polymer material through a die to form the layer of polymer material on a surface of the liner, contacting with a layer of wet plaster material, the liner having the polymer material applied thereon such that the surface of the liner faces away from the wet plaster material, and drying the layer of wet plaster material to form the layer of hardened plaster.

First claim

What is claimed is:

1. A building assembly comprising
a plasterboard comprising:
a layer of hardened plaster material having a first surface and an opposed second surface;
a layer of polymer material having particles of one or more cementitiously-active substances mixed therein; and
a liner between the first surface of the layer of hardened plaster material and the layer of polymer material,
wherein the layer of polymer material forms an outer surface of the plasterboard; and

a functional layer of a foam-based material, a wood material or a mineral wool material; and
a layer of cement-based adhesive having a different composition than the layer of polymer material of the plasterboard and including a first surface disposed in contact with an outer surface of the layer of polymer material of the plasterboard and a second surface opposed to the first surface and bonding the functional layer, wherein the bonding is via a cementitious reaction between the particles of one or more cementitiously-active substances in the polymer layer and the cement-based adhesive.

2. The building assembly of claim 1 , wherein the hardened plaster material comprises a gypsum material.

3. The building assembly of claim 1 , wherein the layer of polymer material has a thickness within a range of 10 μm to 500 μm.

4. The building assembly of claim 1 , wherein the layer of polymer material covers at least 75%, of a surface of the liner that faces away from the first surface of the layer of hardened plaster material.

5. The building assembly of claim 1 , wherein the polymer material comprises calcium carbonate, aragonite, mica, glass fibers, glass beads, or any combination thereof.

6. The building assembly of claim 1 , wherein the polymer material comprises a thermoplastic material.

7. The building assembly of claim 6 , wherein the thermoplastic material comprises ethylene methyl acrylate copolymer, ethylene butyl acrylate copolymer, ethylene vinyl acetate copolymer, polyethylene, thermoplastic polyurethane, a styrene acrylic copolymer, an acrylic copolymer, or any combination thereof.

8. The building assembly of claim 6 , wherein the polymeric material comprises a polymer of (meth)acrylamide, hydroxyl alkyl (meth)acrylate, (meth)acrylic acid, N-(alkoxymethyl)-acrylamide, N-(alkylol)-acrylamide, N-(alkyl)-acrylamide, diacetone (meth) acrylamide, acetoacetoxy alkyl(meth)acrylate or any combination thereof.

9. The building assembly of claim 1 , wherein a mass ratio of the particles of one or more cementitiously-active substances to the polymer material is in the range of 1-70%.

10. The building assembly of claim 1 , wherein the polymer layer includes at least 20% by weight of one or more polymers.

11. The building assembly of claim 1 , wherein the one or more cementitiously-active substances comprise one or more of diatomaceous earth, calcined clay, air floated clay, wollastonite, or granulated blast-furnace slag.

12. The building assembly of claim 1 , wherein the one or more cementitiously-active substances comprise a cement.

13. The building assembly of claim 1 , wherein the one or more cementitiously-active substances comprise one or more polar molecules.

14. The building assembly of claim 1 , wherein the one or more cementitiously-active substances are present in the polymer layer in an amount in the range of 5-60% by weight.

15. The building assembly of claim 1 , wherein the building assembly forms part of an exterior facade of a building.

16. The building assembly of claim 1 , wherein the layer of polymer material has a surface having a roughness of at least 5 μm.

17. The building assembly of claim 1 , wherein the liner is a paper liner.

18. The building assembly of claim 1 , wherein the cement-based adhesive comprises one or more of belite, alite, tricalcium aluminate, or brownmillerite.

19. A method of installing the building assembly of claim 1 , the method comprising:
securing the plasterboard to an exterior surface of a building such that the layer of polymer material faces away from the exterior surface of the building;
applying the cement-based adhesive onto the layer of polymer material; and
bonding, via the cement-based adhesive, the functional layer to the layer of polymer material, wherein the bonding occurs via a cementitious reaction between the particles of one or more cementitiously-active substances and the cement-based adhesive.

Assignees

• Certainteed Gypsum Inc

Inventors

• Kamath Mithun N
• Lai Choung-Houng
• Lemberger Michael J
• Boydston Gerald
• Wiltzius Bryan
• Frailey Nathan
• Dong Eric

Classifications

• B32B2264/101

  Glass · CPC title

• B32B5/024

  Woven fabric · CPC title

• B32B2315/18

  Plaster · CPC title

• B32B27/308

  comprising acrylic (co)polymers · CPC title

• B32B13/14

  next to a fibrous or filamentary layer · CPC title