Cementitious panels with polymeric-film facing material

Patent metadata

Field	Value
Publication number	US-11801662-B2
Application number	US-201916726988-A
Country	US
Kind code	B2
Filing date	Dec 26, 2019
Priority date	Dec 27, 2018
Publication date	Oct 31, 2023
Grant date	Oct 31, 2023

Abstract

Provided are cementitious panels that include a cementitious core material and a plurality of sheets of facing material surrounding the cementitious core material, in which at least one of the plurality of sheets of facing material includes a polymeric-film. The polymeric film may include a thermoplastic composition that has a polymeric matrix including one or more polymeric materials. Additionally, the thermoplastic composition may optionally include a filler material. Additionally, provided are methods of manufacturing such cementitious panels.

First claim

What is claimed is:

1. A cementitious panel, comprising:
a cementitious core material;
a plurality of sheets of facing material sandwiching the cementitious core material, the plurality of sheets of facing material comprising a first sheet of facing material and a second sheet of facing material;
wherein the first sheet of facing material and/or the second sheet of facing material comprises a polymeric-film, the polymeric-film being pervious to water vapor and gases, the polymeric-film containing a thermoplastic composition comprising a polymeric matrix comprising one or more polymeric materials and a filler material, the filler material being dispersed in the polymer matrix, the polymer matrix comprising a network of interconnected pores, the polymer matrix comprising a matrix polymer, wherein the matrix polymer comprises a polyolefin.

2. The cementitious panel of claim 1 , wherein the polymeric matrix further comprises a polyester, a polyamide, a polyimide, a polysulfonate, a polytetrafluoroethylene, and/or a polyvinylidene difluoride.

3. The cementitious panel of claim 1 , wherein the filler material comprises one or more organic filler materials and/or inorganic filler materials.

4. The cementitious panel of claim 1 , wherein the filler material comprises particles and/or discrete domains of a micro-scale size, the particles and/or discrete domains having an average cross-sectional dimension from 1 μm to 2000 μm.

5. The cementitious panel of claim 1 , wherein the filler material comprises particles and/or discrete domains of a nano-scale size, the particles and/or discrete domains having an average cross-sectional dimension from 1 nm to 1000 nm.

6. The cementitious panel of claim 3 , wherein the organic filler material comprises a superabsorbent polymer.

7. The cementitious panel of claim 3 , wherein the inorganic filler material comprises siliceous particles and/or particles of aluminum oxides, titanium oxides, zinc oxides, antimony oxides, zirconia, magnesia, zinc sulfide, barium sulfate, strontium sulfate, cesium oxide, yttrium oxide, colloidal yttria, zirconia, colloidal zirconia, calcium carbonate, magnesium carbonate, and/or magnesium hydroxide.

8. The cementitious panel of claim 3 , wherein the inorganic filler material comprises a polyphosphazene, a polysilane, a polysiloxane, a polygermane, a polymeric sulfur, a polymeric selenium, a silicone, an aluminum-containing polymer, and/or a ferrocene-containing polymer.

9. The cementitious panel of claim 1 , wherein the filler material comprises one or more pigments, the one or more pigments comprising an azo compound, a heterocyclic pigment, a bicyclic pigment, and/or a polycyclic pigment.

10. The cementitious panel of claim 1 , wherein the filler material comprises a complex and/or a mixture, the complex and/or mixture comprising one or more superabsorbent polymers and one or more inorganic filler materials.

11. The cementitious panel of claim 1 , wherein the filler material comprises a swellable material.

12. The cementitious panel of claim 11 , wherein the swellable material comprises a superabsorbent polymer and an inorganic filler material crosslinked and/or admixed with the superabsorbent polymer.

13. The cementitious panel of claim 1 , wherein the filler material comprises a porous filler material.

14. The cementitious panel of claim 13 , wherein the pores have a nano-scale size comprising an average cross-sectional dimension from 1 nm to 1000 nm.

15. The cementitious panel of claim 13 , wherein the pores have a micro-scale size comprising an average cross-sectional dimension from 0.1 μm to 20 μm.

16. The cementitious panel of claim 1 , wherein the first sheet of facing material and/or the second sheet of facing material comprises one or more coatings and/or a plurality of layers.

17. The cementitious panel of claim 16 , wherein the one or more coatings comprises a filler material.

18. The cementitious panel of claim 16 , wherein the one or more coatings comprises a porous siliceous coating formed from one or more alkoxysilanes.

19. The cementitious panel of claim 16 , wherein the one or more coating comprises pores that have an average cross-sectional dimension from 0.1 nm to 25 nm.

20. The cementitious panel of claim 1 , wherein the cementitious panel exhibits a surface water resistance according to ASTM C-473 such that the panel absorbs less than 10% of water.

21. A cementitious panel, comprising:
a cementitious core material;
a plurality of sheets of facing material sandwiching the cementitious core material, the plurality of sheets of facing material comprising a first sheet of facing material and a second sheet of facing material;
wherein the first sheet of facing material and/or the second sheet of facing material comprises a polymeric-film, the polymeric-film having a thickness from 0.5 μm to 500 μm, the polymeric-film being pervious to water vapor and gases, the polymeric-film containing a thermoplastic composition comprising a polymeric matrix comprising one or more polymeric materials and a filler material, the filler material being dispersed in the polymer matrix, the polymer matrix comprising a network of interconnected pores, the polymer matrix comprising a matrix polymer, wherein the matrix polymer comprises a polyolefin.

22. The cementitious panel of claim 3 , wherein the inorganic filler material comprises a swellable clay.

Assignees

• Nat Gypsum Properties Llc
• Gold Bond Building Products Llc

Inventors

• Busche Bradley J
• Miatudila Ma-Ikay
• Randall Brian G
• Bailey Joseph J

Classifications

• B32B13/12 Primary

  of synthetic resin · CPC title

• B28B19/0046

  to plastics · CPC title

• B32B3/26

  characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids {(foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205); characterised by an apertured layer} · CPC title

• B32B27/20

  using fillers, pigments, thixotroping agents · CPC title

• C08K5/0041

  Optical brightening agents, organic pigments · CPC title