Cementitious Panels with Swellable Materials and Methods of Providing a Moisture or Water Barrier in Cementitious Panels Using Swellable Materials

Patent metadata

Field	Value
Publication number	US-2023366197-A1
Application number	US-202318356301-A
Country	US
Kind code	A1
Filing date	Jul 21, 2023
Priority date	Dec 27, 2018
Publication date	Nov 16, 2023
Grant date	—

Abstract

Provided are cementitious panel that include a swellable material within a core layer, a dense layer, and/or a sheet of facing material that make up a cementitious panel, as well as methods of manufacturing such cementitious panels that include a swellable material and methods of providing a moisture or water barrier in a cementitious panel.

First claim

What is claimed is:

1 - 69 . (canceled)

70 . A cementitious panel, comprising:
a core layer comprising a cementitious material; a plurality of sheets of facing material surrounding the core layer, the plurality of sheets of facing material comprising a first sheet of facing material and a second sheet of facing material; a first dense layer comprising a cementitious material defining an interface between the core layer and the first sheet of facing material; and one or more swellable materials comprising a clay, wherein the first dense layer comprises at least one swellable material of the one or more swellable materials.

71 . The cementitious panel of claim 70 , wherein the core layer further comprises at least one swellable material of the one or more swellable materials, the one or more swellable materials of the core layer comprising from 0.1 wt. % to 90 wt. % of the core layer, based on the total weight of the core layer.

72 . The cementitious panel of claim 70 , wherein the first dense layer comprises the one or more swellable materials in an amount of from 0.1 wt. % to 90 wt.% based on the total weight of the first dense layer.

73 . The cementitious panel of claim 70 , wherein the one or more swellable materials comprise 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.

74 . The cementitious panel of claim 70 , wherein the one or more swellable materials comprise 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 1,000 nm.

75 . The cementitious panel of claim 70 , wherein the one or more swellable materials have the capability to swell to a volume that is from 2 to 100 times the non-swollen volume of the one or more swellable materials.

76 . The cementitious panel of claim 70 , wherein the one or more swellable materials have the capability to absorb from 2 to 30 times its weight in distilled water.

77 . The cementitious panel of claim 70 , wherein the one or more swellable materials comprise one or more phyllosilicates.

78 . The cementitious panel of claim 77 , wherein at least one of the one or more phyllosilicates comprises bentonite.

79 . The cementitious panel of claim 70 , wherein the one or more swellable materials comprise an encapsulated or coated swellable material.

80 . The cementitious panel of claim 70 , wherein the cementitious panel exhibits a surface water resistance according to ASTM C-473 such that the cementitious panel absorbs less than 10% of water.

81 . The cementitious panel of claim 70 , wherein the cementitious panel comprises void volumes in the form of one or more holes, punctures, cracks, cuts, or perforations, at least some of the void volume at least partially blocked by the one or more swellable materials having been swollen by absorbing water or moisture, wherein the holes optionally include fastener holes.

82 . The cementitious panel of claim 70 , wherein the cementitious panel further comprises a second dense layer.

83 . A method of providing a moisture or water barrier in a cementitious panel, the method comprising:
contacting one or more swellable materials in a cementitious panel with a first quantity of moisture or water, the one or more swellable materials comprising a clay; absorbing with the one or more swellable materials at least some of the first quantity of moisture or water with the one or more swellable materials swelling to at least twice the non-swollen volume of the one or more swellable materials; at least partially blocking a void volume in the cementitious panel with the one or more swellable materials swollen from having absorbed at least some of the first quantity of water; and preventing or mitigating a second quantity of moisture of water from penetrating through the void volume at least partially blocked by the one or more swollen swellable materials.

84 . The method of claim 83 , wherein the void volume comprises one or more holes, punctures, cracks, cuts, or perforations.

85 . The method of claim 83 , wherein the void volume comprises one or more fastener holes.

86 . A cementitious panel, comprising:
a core layer comprising a cementitious material; a plurality of sheets of facing material surrounding the core layer, the plurality of sheets of facing material comprising a first sheet of facing material and a second sheet of facing material; a first dense layer comprising a cementitious material defining an interface between the core layer and the first sheet of facing material, the first dense layer formed by applying the cementitious material to an inner side of the first sheet of facing material, the first dense layer having a higher concentration of gypsum crystals and a lower concentration of void volumes than the core layer, wherein at least a portion of the first dense layer penetrates into the first sheet of facing material; and one or more swellable materials comprising a clay, wherein the first dense layer comprises at least one swellable material of the one or more swellable materials.

87 . The cementitious panel of claim 86 , wherein the core layer further comprises at least one swellable material of the one or more swellable materials, the one or more swellable materials of the core layer comprising from 0.1 wt. % to 90 wt. % of the core layer, based on the total weight of the core layer.

88 . The cementitious panel of claim 86 , wherein the first dense layer comprises the one or more swellable materials in an amount of from 0.1 wt. % to 90 wt.% based on the total weight of the first dense layer.

89 . The cementitious panel of claim 86 , wherein the one or more swellable materials comprise 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.

90 . The cementitious panel of claim 86 , wherein the one or more swellable materials comprise 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 1,000 nm.

91 . The cementitious panel of claim 86 , wherein the one or more swellable materials have the capability to swell to a volume that is from 2 to 100 times the non-swollen volume of one or more swellable materials.

92 . The cementitious panel of claim 86 , wherein the one or more swellable materials have the capability to absorb from 2 to 30 times its weight in distilled water.

93 . The cementitious panel of claim 86 , wherein the one or more swellable materials comprise one or more phyllosilicates.

94 . The cementitious panel of claim 93 , wherein at least one of the one or more phyllosilicates comprises bentonite.

95 . The cementitious panel of claim 86 , wherein the one or more swellable materials comprise an encapsulated or coated swellable material.

96 . The cementitious panel of claim 86 , wherein the cementitious panel exhibits a surface water resistance according to ASTM C-473 such that the cementitious panel absorbs less than 10% of water.

Assignees

• Gold Bond Building Products Llc

Inventors

• Stav Eli
• Bailey Joseph J
• Busche Bradley G
• Randall Brian G

Classifications

• B28B19/0092

  to webs, sheets or the like, e.g. of paper, cardboard · CPC title

• E04B1/6815 Primary

  Expansion elements specially adapted for wall or ceiling parts · CPC title

• B32B3/266

  characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12 · CPC title

• B32B5/022

  Non-woven fabric · CPC title

• B32B5/024

  Woven fabric · CPC title