Plastic coated composite building boards and method of making same

Patent metadata

Field	Value
Publication number	US-9885179-B2
Application number	US-201615044639-A
Country	US
Kind code	B2
Filing date	Feb 16, 2016
Priority date	Aug 29, 2008
Publication date	Feb 6, 2018
Grant date	Feb 6, 2018

Abstract

Disclosed are composite building boards and associated manufacturing methods. The composite boards may include, for example, one or more slurry layers with embedded fibrous mats. An exterior plastic coating is mechanically adhered to the underlying slurry layer. The plastic layer chemically bonds and cross-links with polymer additives within the slurry layer. The result is an integrated polymer matrix with greatly improved durability and surface strength.

First claim

What is claimed is:

1. A method for constructing a composite structural panel in a continuous manufacturing process, the method comprising:
providing a porous mat having interior and exterior surfaces;
penetrating the porous mat with a dense cementitious slurry layer to substantially cover the exterior surface;
forming a boundary layer with the slurry, the boundary layer substantially covering the exterior surface of the porous mat;
delivering a core slurry layer onto the interior surface of the porous mat;
adhering a molten coating, the majority of which comprises a non-curing thermoplastic polymer, over the boundary layer.

2. The method as described in claim 1 wherein the thermoplastic coating forms a polymer matrix with the composite structural panel.

3. The method as described in claim 1 wherein the thermoplastic coating is applied prior to the curing of the boundary layer.

4. The method as described in claim 1 wherein the thermoplastic coating is applied after the curing of the boundary layer.

5. The method as described in claim 1 wherein the thermoplastic coating is applied prior to the curing of the core.

6. The method as described in claim 1 wherein the thermoplastic coating is applied after the curing of the core.

Assignees

• Certainteed Gypsum Inc

Inventors

• Hauber Robert J
• Boydston Gerald D

Classifications

• B28B19/0092 Primary

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

• B32B2255/26

  Polymeric coating · CPC title

• B32B2307/554

  Wear resistance · CPC title

• B28B23/0006

  the reinforcement consisting of aligned, non-metal reinforcing elements · CPC title

• B32B13/04

  comprising such {water setting} substance as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a glass layer B32B17/06)} · CPC title