Laminated foam composite backer board for wet space construction

Patent metadata

Field	Value
Publication number	US-12410620-B2
Application number	US-202318458711-A
Country	US
Kind code	B2
Filing date	Aug 30, 2023
Priority date	Jun 21, 2016
Publication date	Sep 9, 2025
Grant date	Sep 9, 2025

Abstract

A composite backer board for wet space construction is disclosed, along with a method of producing the backer board. The board includes a rigid foam core of a suitable thickness for wet space construction. A first fabric layer is fixed to at least one face of the rigid foam core with a polymeric adhesive. A first polymer layer is on the first fabric layer in which the polymer layer is dimensionally stable parallel to the face of the rigid foam core. A second fabric layer is on the first polymer layer opposite the first fabric layer and forms a first face that is amenable to thin set mortar and related compositions in wet space construction.

First claim

The invention claimed is:

1. A composite backer board for wet space construction, said board comprising:
a rigid foam core of a suitable thickness for wet space construction;
a polymeric adhesive layer fixed directly to at least one face of the rigid foam core;
a first fabric layer fixed directly to the polymeric adhesive layer;
a first polymer layer affixed to said first fabric layer in which the polymer layer is dimensionally stable parallel to said face of said rigid foam core; and
a second fabric layer affixed to said first polymer layer opposite said first fabric layer and forming a first face that is amenable to thin set mortar and related compositions in wet space construction.

2. A composite backer board according to claim 1 and further comprising:
a second polymeric adhesive layer fixed directly to an opposite face of the rigid foam core;
a third fabric layer fixed directly to the second polymeric adhesive layer;
a second polymer layer affixed to said third fabric layer in which the polymer layer is dimensionally stable parallel to said face of said rigid foam core; and
a fourth fabric layer affixed to on said second polymer layer opposite said third fabric layer and forming a second face that is amenable to thin set mortar and related compositions in wet space construction.

3. A composite backer board according to claim 1 wherein said polymer layer is selected from the group consisting of thermoplastic material and thermosetting material.

4. A composite backer board according to claim 1 wherein said foam core layer is comprised of foam selected from the group consisting of extruded polystyrene (XPS), expanded polystyrene (EPS), polyethylene-terephthalate (PET), or polyisocyanurate (ISO).

5. A composite backer board according to claim 1 wherein said foam core layer comprises extruded polystyrene foam.

6. A composite backer board according to claim 1 wherein said foam composite backer board has a water vapor permeability of 0.5 perms or less measured according to ASTM E96 Procedure E (100° F., 90% RH) for ½ inch thick of board.

7. A composite backer board according to claim 1 wherein said composite backer board has a flexural strength of at least 250 PSI when measured according to ASTM C947.

8. A composite backer board according to claim 1 wherein said first polymer layer has a modulus of elasticity and tensile strength that when combined with the thickness of the facer, provides the necessary flexural stiffness and strength for tile applications.

9. A composite backer board according to claim 8 wherein said first polymer layer has a modulus of elasticity of at least 200,00 PSI and a tensile strength of at least 25 lb./inch.

10. A composite backer board according to claim 1 wherein said first fabric layer has a thickness sufficient to prevent the adhesive of the polymeric adhesive layer from entirely saturating the first fabric's bonding sites.

11. A composite backer board according to claim 10 wherein said first fabric layer has a thickness that defines a weight of between about 0.75 and 2.25 osy.

12. A composite backer board according to claim 1 wherein said first fabric layer is selected from the group consisting of a polyolefin-based scrim or knitted, woven, or nonwoven fabric.

13. A composite backer board for wet space construction, said board comprising:
a rigid foam core of a suitable thickness for wet space construction;
a polymeric adhesive layer, fixed directly to a face of the rigid foam core;
a first facer layer having a first fabric layer on a surface thereof, the first fabric layer fixed directly to the polymeric adhesive layer;
a second polymeric adhesive layer fixed directly to an opposite face of the rigid foam core; and
a second facer layer having a second fabric layer on a surface thereof, the second fabric layer fixed directly to the second polymeric adhesive layer.

14. A composite backer board according to claim 13 , wherein said first and second facer layers include:
two fabric layers having a dimensionally stable polymeric film disposed therebetween.

15. A composite backer board according to claim 14 wherein at least one of said fabric layers is bondable to thin set mortar.

16. A composite backer board according to claim 13 wherein said foam core is comprised of foam selected from the group consisting of extruded polystyrene (XPS), expanded polystyrene (EPS), polyethylene-terephthalate (PET), or polyisocyanurate (ISO).

17. A composite backer board according to claim 13 wherein said foam comprises extruded polystyrene.

Assignees

• Schluter Systems Lp

Inventors

• Nielsen Peter
• Dejesus William M

Classifications

• B32B2266/0214

  Materials belonging to B32B27/00 · CPC title

• B32B2250/05

  5 or more layers · CPC title

• B32B2305/18

  Fabrics, textiles · CPC title

• B32B2305/022

  Foam · CPC title

• B32B37/153

  at least one layer is extruded and immediately laminated while in semi-molten state · CPC title