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EP2235281A2 - Panneaux cimentaires à bords renforcés qui résistent aux dommages provoqués par des impacts - Google Patents
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EP2235281A2 - Panneaux cimentaires à bords renforcés qui résistent aux dommages provoqués par des impacts - Google Patents

Panneaux cimentaires à bords renforcés qui résistent aux dommages provoqués par des impacts

Info

Publication number
EP2235281A2
EP2235281A2 EP08869157A EP08869157A EP2235281A2 EP 2235281 A2 EP2235281 A2 EP 2235281A2 EP 08869157 A EP08869157 A EP 08869157A EP 08869157 A EP08869157 A EP 08869157A EP 2235281 A2 EP2235281 A2 EP 2235281A2
Authority
EP
European Patent Office
Prior art keywords
board
edges
coating
cementitious
core
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP08869157A
Other languages
German (de)
English (en)
Inventor
David Bruce Mcdonald
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
United States Gypsum Co
Original Assignee
United States Gypsum Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by United States Gypsum Co filed Critical United States Gypsum Co
Publication of EP2235281A2 publication Critical patent/EP2235281A2/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/043—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of plaster

Definitions

  • the present invention relates generally to cementitious panels or boards, including cement board, gypsum board, cement fiberboard, gypsum cellulose fiberboard (gypsum fiberboard) wherein the cementitious board is reinforced on its edges by a coating of an elastic composition unaffected by alkali attack.
  • the present invention generally prevents damage from transportation, moving or nailing during installation.
  • cement panels or boards contain a core formed of a cementitious material which may be interposed between two layers of facing material.
  • the facing materials employed typically share the features of high strength, high modulus of elasticity, and light weight to contribute flexural and impact strength to the high compressive strength, but brittle material forming the cementitious core.
  • the facing material employed with cement panels is fiberglass fibers or fiberglass mesh that is embedded in the cementitious slurry core. Fiberglass performs particularly well in this application. Fiberglass provides greater physical and mechanical properties to the cement board. Fiberglass is also an efficient material to reinforce the cement panels because of its relatively low cost when compared with other high modulus materials.
  • Cementitious backerboard comprises a panel having a core layer of light-weight concrete with each of the two faces covered with a layer of reinforcing fabric bonded to the core layer.
  • Such cementitious backerboards are described in the U.S. Pat. No. 3,284,980 P. E. Dinkel, which is incorporated herein by reference in its entirety. These panels are nailable and
  • [005] are readily fastened to the framing members. Furthermore they are substantially unaffected by water and consequently find extensive use in wet areas such as shower enclosures, bathtub surrounds, kitchen areas and entryways, as well as on building exteriors.
  • Cementitious backerboards are generally produced using a core mix of water, light-weight aggregate (e.g., expanded clay, expanded slag, expanded shale, perlite, expanded glass beads, polystyrene beads, and the like) and a cementitious material (e.g., Portland cement, magnesia cement, alumina cement, gypsum and blends of such materials).
  • light-weight aggregate e.g., expanded clay, expanded slag, expanded shale, perlite, expanded glass beads, polystyrene beads, and the like
  • a cementitious material e.g., Portland cement, magnesia cement, alumina cement, gypsum and blends of such materials.
  • a foaming agent as well as other additives can be added to the mix.
  • the reinforcing fabric most generally employed is a fiber glass scrim and, in particular, is a woven mesh of vinyl coated fiber glass yarns.
  • the yarn count per 2.54 centimeter (1 inch) of the fabric varies from 8x8 to 12x20, depending upon the size of the openings in the mesh or scrim for passage of the bonding material through the fabric.
  • Other pervious fabrics having suitable tensile strength, alkali resistance and sufficiently large pores or openings may be employed.
  • the reinforcing fabric is bonded to the surface of the core layer with a thin coating of Portland cement slurry, with or without some fine aggregate added.
  • the core mix can be sufficiently fluid to be vibrated or forced through the openings of the reinforcing fabric to cover the fabric and to bond it to the core layer. This is described in U.S. Pat. No. 4,450,022 of Galer, the disclosure of which is incorporated herein by reference in its entirety.
  • Fiberglass has a major disadvantage. It lacks resistance to chemical attack from the ingredients of the cements.
  • Common cements such as Portland cement, provide an alkaline environment when in contact with water, and the fiberglass yarn used in reinforcement fabrics is degraded in these highly alkaline conditions.
  • protective polymeric coatings such as polyvinyl chloride solution coatings, are applied to the fiberglass. Although these coatings reduce fiberglass degradation, the integrity of the protective coating on the fiberglass yarns is critical to the success of the concrete panel.
  • the fiberglass rapidly degrades with heat, which typically occurs during the curing of the cementitious boards. Therefore, excess fiberglass must be included to ensure a minimum amount of strength over the life of the cement boards.
  • cementitious panel is reinforced with a fabric at its surface and the longitutudinal edges are reinforced with a network of fibers.
  • a continuous band of synthetic alkali-resistant, non-woven fabric completely covers the edge areas of the board with a U-shaped reinforcing mesh to make the edges resistant to impact.
  • an improved cementitious panel e.g. a cement panel that is reinforced on its edges without the need for the use of reinforcing fabric scrim or non-woven fabric layers on the edges of the cement panels as commonly used in some commercial cement panel.
  • the present invention relates to a new and improved cementitious panels such as cement board, gypsum board, gypsum cellulose fiber board, etc. that is reinforced from damage on its edges by an elastic coating composition applied to each of the edges of the cement panel.
  • the cementitious panel includes a core layer made of a cement composition and typically has reinforcing fiberglass mesh or scrim on the opposing surfaces of the cement core that is embedded into the cementitious core.
  • the fiberglass mesh or scrim is commonly treated with a polyvinyl chloride thermal melt coating to resist degradation under alkaline conditions.
  • the bottom scrim or mesh layer is commonly extended over the panel edge and overlap at least a portion of the top mesh or scrim to which it is adhesively attached.
  • the elastic coating can be applied over the scrim on both of the opposed surfaces of the core and over scrim that extends over the edges of the cement panel.
  • the term "scrim" means a fabric having an open construction used as a base fabric or a reinforcing fabric.
  • plural weft yarns having both an upward diagonal slope and a downward diagonal slope are located between plural longitudinal warp yarns located on top of the weft yarns and below the weft yarns.
  • the scrim or mesh layer embedded into the surfaces of the cementitious core and the edge can also be wrapped with a paper layer that extends over the scrim or mesh layer and the edge of the panel to a portion of the top mesh layer.
  • the border edge regions of the cement panels, including the cement core and mesh layers and any overlapping paper layer are coated with the elastic coating to strengthen the edges and prevent impact damage to the edge during nailing near the edge of the panel.
  • the cementitious panel such as a gypsum wood fiberboard
  • the cementitious panel can be adequately protected with only the coating of the current invention without the use of a fabric or mesh held to the edges of the cement core by an adhesive composition in accordance with standard industry practices.
  • a cementitious panel such as gypsum board which has a paper layer on both surfaces of the gypsum core can be protected from spalling or impact damage by coating the longitudinal edges of the gypsum board with the elastomer coating with or without a layer of paper over the edges.
  • FIG. 1 is a perspective view of a cement panel coated on both edges with an elastic material to protect the edges from damage in accordance with an embodiment of the present invention.
  • FIG. 2 is a side view along view M-Il of the cement panel with a layer of embedded scrim or mesh wrapped around the edges and the scrim layer embedded in the core on the opposing side of the cement core and coated by an elastic material coating in accordance with the embodiment of FIG. 1.
  • FIG. 3 shows the coating also applied to the opposed side edges of the board.
  • FIG. 4 shows a side view of another embodiment in which the back scrim or mesh layer and the edge can also be wrapped with a paper layer that extends over the back mesh and the edge of the panel to a portion of the front mesh layer.
  • FIG. 5 shows another embodiment of the present invention in which, the cement board can be adequately protected with only the coating of the current invention without the use of a fabric or mesh held to the edges of the cement core by an adhesive composition.
  • FIG. 6 is a side cross sectional view of a conventional cement board.
  • FIG. 7 is a cross sectional view of a cement board of the present invention
  • FIG. 8 is a photograph of a conventional cement panel nailed to a wooden frame with a major spalling failure near the edges.
  • FIG. 9 is a photograph of a cement panel coated on its edge with the elastic coating in accordance with the present invention.
  • the present invention is a new and improved cement panel reinforced on one or more of its edges with a coating of an elastic material.
  • FIG. 1 is a perspective view of a cement board 10 having a cement core 12 and scrim wrapped about the core 12, and a coating of an elastic material 20 on opposed top and bottom edges 19, 21 in accordance with an embodiment of the present invention.
  • Elastic material 20 protects the edges 19, 21 from damage.
  • the core layer 12 is made of a cement composition.
  • the polyvinyl chloride coated reinforcing fiberglass mesh or scrim is wrapped about the core 12 to form a front layer 11 and a back layer 13.
  • the back scrim or mesh layer 13 is commonly extended to its edge 27 over the panel edge 19 and overlaps at least a portion of the front mesh or scrim 11 and is embedded in the cement core 12.
  • the term "scrim" means a fabric having an open construction used as a base fabric or a reinforcing fabric.
  • plural weft yarns having both an upward diagonal slope and a downward diagonal slope are located between plural longitudinal warp yarns located on top of the weft yarns and below the weft yarns.
  • FIG. 2 is a side view of the cement board 10.
  • the cement board 10 includes a core layer 12 made of a concrete composition. Core layer 12 is covered by top layer 11 and bottom layer 13 made of fiberglass scrim or mesh.
  • edges 21 of the core layer 12, and end portions of the scrim front layer 11 and back layer 13 are wrapped to produce rounded edge corners 22. Because of its cementitious nature, a cement board or panel may have a tendency to be relatively brittle at its edges which often serve as points of attachment for the boards.
  • Using the selected elastic polymer 20 to coat the edge 21 of the cement board 10 and the portions of the front and back scrim faces adjacent these edges gives elasticity to the opposed end portions of the board 10.
  • the coated end portions extend a distance "A" of about 0.635 to 7.62 cm. (0.25 to 3.0 inches) typically about 0.635 cm to 2.54 cm (0.25 to 1.0 in.) from each of the respective edge 21 , as shown in FIG. 2 with the coated edges 20 extending over a portion of the front scrim layer 11 and the back scrim layer 13.
  • edge 21 By coating the edge 21 , the strength of the cement board edges is augmented. Coatings are typically applied in two or three coats.
  • Cementitious boards are generally used as a substrate for ceramic tile and coatings used must be compatible with this application.
  • ANSI specifications 118.10 and 118.12 outline product performance for Waterproofing and Crack isolation used in conjunction with ceramic tiles. Coatings meeting the tile bonding performance requirements of these ANSI specifications are regarded as suitable for this invention
  • Elasticity or elongation is measured in the coatings industry using ASTM D522-93a (effective 2001 ). This is a standard test method for mandrel bend test of attached organic coatings wherein the measure of the coating independent of the substrate.
  • the coating 20 may also be applied to the opposed side edges 31 , 33 as shown in FIG. 3.
  • FIG. 4 shows another embodiment of a panel 40 in which the bottom scrim or mesh layer and the edge can also be wrapped with a paper layer 29 that extends over the bottom mesh and the edge of the panel to a portion of the top mesh layer.
  • the border edge regions of the cement panels, including the cement core and mesh layers and any overlapping paper layer are coated with the elastic coating to strengthen the edges and prevent impact damage to the edge during nailing near the edge of the panel.
  • the coating may be applied such that the boards retain sufficient structural integrity during handling and attachment without the need for use of a reinforcing fabric layer or scrim, such as in the case of cement fiber board or gypsum wood fiber board.
  • FIG. 5 shows another embodiment of a panel 50 of the present invention in which, the cement board can be adequately protected with only the coating 20 of the current invention without the use of a fabric or mesh held to the edges of the cement core by an adhesive composition.
  • the elastic coating 20 may be applied by spraying, pouring, sprinkling, dipping, and painting onto the edges and is then dried after application so as to stabilize reinforcement of the edges of the cement board from damage or spalling.
  • the coated edges of the cement board also have the advantage of producing a curved or rounded edge on the cement board, which improves handling of the board during transportation and installation.
  • the elastomeric coating is applied by spraying on the coating approximately 7.84 cm. (3 inch) from each edge and allowed to dry to a uniform smooth surface over the top and bottom layers 11 of the cement board 10. It is contemplated that the coating will range from about 2 to 3 mm in thickness over the surface of the outer layers and taper off into the central portion of the cement board 10.
  • the elastomer coating is a latex rubber composition that has the desired elasticity as measured by its percent elongation of about 100% to about 1000% such as found in natural rubber,
  • elastomers that can be used typically have an elastic elongation of from 500% to 1000%.
  • the elastomers more typically have an elongation in the range of about 400% to about 600% and which typically also provides a water resistant property to the coated edges of the cement board panel.
  • Elastomers can include co-polymers of rubber and at least one other alpha-olefin and/or terpolymers rubber of ethylene at least one other alpha- olefin, and a minor proportion of at least one other alpha-olefin, and a minor proportion of at least one co-polymehzable polyene.
  • the copolymer rubber is preferably a styrene copolymer e.g. styrene- butadiene copolymer.
  • Such copolymer may be the only rubber in the elastomer material, but typically, the elastomeric material comprises a blend of the copolymer.
  • Coating compositions that have been found to have the necessary degree of elasticity include polyisoprene, polybutadiene, polyisobutylene and liquid forms of natural rubbers.
  • a liquid rubber product with a high elongation and which adheres to cement board and thin coat mortars and basecoats have been found to be particularly effective.
  • a typical coating composition that has been found to give good results is a liquid rubber product that is sold under the tradename LATICRETE ® Watertight Floor N' Wall Waterproofing, made by Laticrete International, Inc., Laticrete Park North, Bethany, CT 06524.
  • This liquid rubber product is ordinarily used to protect substrates like concrete gypsum wallboard plywood cement backer board and gypsum plaster that are used under ceramic tile and stone in wet areas, such as bathrooms.
  • the liquid rubber has a reported elongation of 400% and a tensile strength of 5.3 MPa (765 psi.).
  • FIG. 6 illustrates a schematic partial side view of a conventional DUROCK ® brand cement board 60 available from USG Corporation, Chicago, IL 60661.
  • Board 60 has a core 12, fiberglass scrim providing a front fiberglass scrim layer 11 and back fiberglass scrim layer 13, and a paper layer 35.
  • FIG. 7 shows a modified board 70 in which LATICRETE ® Watertight liquid rubber product commercially available from Laticrete International Inc., Bethany CT 06524 with a elongation specification of 400% was painted as a coating 20 on the edges of several sample of USG Corporation's DUROCK ® brand cement board to produce a board structure, having the liquid rubber coating wrapped around the wrapped edges of the cement board for 0.635 to 2.54 cm. (% in. to 1 in.) in a longitudinal direction.
  • LATICRETE ® Watertight liquid rubber product commercially available from Laticrete International Inc., Bethany CT 06524 with a elongation specification of 400% was painted as a coating 20 on the edges of several sample of USG Corporation's DUROCK ® brand cement board to produce a board structure, having the liquid rubber coating wrapped around the wrapped edges of the cement board for 0.635 to 2.54 cm. (% in. to 1 in.) in a longitudinal direction.
  • spalling is the chipping or flaking of concrete, bricks, or other masonry which is typically found when there is improper drainage or venting and freeze/thaw cycling exists. A typical example of spalling in a nailed cement panel that has not been coated with the protective elastic coating of the invention is shown in the photograph in FIG. 8.
  • a cement board 70 in FIG. 9 has a protective elastic coating 20, of Example 1 , on its edge of its longitudinal front surface 11 and the back surface 13 (not shown in FIG. 9) and is resistant to spalling when nailed on the top and bottom edges of longitudinal front surface 11 of the board.
  • the elastic coatings listed in Table 1 above are only intended to be representative and are not in any way limiting.
  • the elastomeric materials that can be used include one or more of large number of latex polymers, epoxies, acrylates and polyurethane polymers that have the desired elastic elongation properties and which will form a strong resilient coating on the edges which will resist chipping or breaking when subjected to impact during shipment and installation.
  • the coated board samples 70 were drilled 1 A inch from the wrapped edge of each panel. These sections were then tested according to ASTM C473 effective 2007 Standard Test Methods for Physical Testing of Gypsum Panel Products for nail performance. Control samples were tested without coatings. The results are reported in Table 2 below.
  • control specimens had an average load strength value of 85 LBS, compared to coated specimens having load values of 120 to 160 lbs. Three of the coatings provided an 80% improvement in nail pull results.
  • the coefficient of variation (COV) for the two materials with higher elongation with higher elongation was substantially lower than the acrylic latex and acrylic latex enamel paints. This indicates that a more consistent result may be obtained through use of coatings having higher elongation.
  • Elastomeric Coatings of Table 1 are to be used in repeating the test of nail impact of Example 2 with a control and two coats of each of the coatings for samples of (1 ) DUROCK® brand cement board; (2) FIBEROCK® brand gypsum fiberboard and (3) HARDIE BACKERTM brand 14 inch cement board, available from JAMES HARDIE Building Products, Mission Viejo, CA. Similar improvement in nail impact strength is expected with the three samples of cement and gypsum board.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)
  • Finishing Walls (AREA)
  • Panels For Use In Building Construction (AREA)
  • Aftertreatments Of Artificial And Natural Stones (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)

Abstract

Panneau cimentaire à bords renforcés par un revêtement d'une composition élastique qui assure au panneau une résistance améliorée à l'arrachement de clous. Selon un mode de réalisation préféré, le revêtement assure une protection supplémentaire des bords du panneau contre les dommages provoqués par des impacts et la fissuration ou « l'éclatement » du panneau pendant la manipulation et l'installation, par exemple pendant le clouage, en particulier quand le panneau est cloué à une structure près des bords du panneau cimentaire. Le panneau cimentaire comprend typiquement un panneau de fibres de gypse, un panneau de revêtement en gypse recouvert de papier, et un panneau de ciment ayant une couche formant âme faite d'une composition de ciment léger. Sur les bords du panneau, le revêtement est appliqué de sorte à recouvrir la partie du panneau s'étendant à partir du bord sur une distance d'environ 0,635 cm à 5,08 cm (un quart-de-pouce à deux pouces), typiquement de 0,635 cm à 2,54 cm (un quart-de-pouce à un pouce), depuis chacun des bords sur les deux couches de surface externe, supérieure et inférieure, du panneau cimentaire, pour former des bords arrondis.
EP08869157A 2007-12-28 2008-12-18 Panneaux cimentaires à bords renforcés qui résistent aux dommages provoqués par des impacts Withdrawn EP2235281A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US1734307P 2007-12-28 2007-12-28
PCT/US2008/087478 WO2009085981A2 (fr) 2007-12-28 2008-12-18 Panneaux cimentaires à bords renforcés qui résistent aux dommages provoqués par des impacts

Publications (1)

Publication Number Publication Date
EP2235281A2 true EP2235281A2 (fr) 2010-10-06

Family

ID=40825017

Family Applications (1)

Application Number Title Priority Date Filing Date
EP08869157A Withdrawn EP2235281A2 (fr) 2007-12-28 2008-12-18 Panneaux cimentaires à bords renforcés qui résistent aux dommages provoqués par des impacts

Country Status (5)

Country Link
EP (1) EP2235281A2 (fr)
JP (1) JP2011509194A (fr)
CA (1) CA2710834A1 (fr)
CL (1) CL2008003916A1 (fr)
WO (1) WO2009085981A2 (fr)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015103120A2 (fr) 2013-12-30 2015-07-09 Saint-Gobain Placo Sas Panneaux de construction à résistance de surface accrue
US11173629B2 (en) 2016-08-05 2021-11-16 United States Gypsum Company Continuous mixer and method of mixing reinforcing fibers with cementitious materials
US10272399B2 (en) 2016-08-05 2019-04-30 United States Gypsum Company Method for producing fiber reinforced cementitious slurry using a multi-stage continuous mixer
US11224990B2 (en) 2016-08-05 2022-01-18 United States Gypsum Company Continuous methods of making fiber reinforced concrete panels
US10981294B2 (en) 2016-08-05 2021-04-20 United States Gypsum Company Headbox and forming station for fiber-reinforced cementitious panel production
AU2024264896A1 (en) * 2023-05-02 2025-11-27 UBIQ Technology Pty Ltd Ballistic and fire resistant panel wall system

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4916004A (en) * 1986-02-20 1990-04-10 United States Gypsum Company Cement board having reinforced edges
JP2003253807A (ja) * 2002-03-04 2003-09-10 Chiyoda Ute Co Ltd 腰壁パネル及びその施工方法
US20040219845A1 (en) * 2003-04-29 2004-11-04 Graham Samuel E. Fabric reinforced cement
KR200361112Y1 (ko) * 2004-06-04 2004-09-07 주식회사 이수테크산업 쿠션재가 부착된 석고패널

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO2009085981A2 *

Also Published As

Publication number Publication date
JP2011509194A (ja) 2011-03-24
CA2710834A1 (fr) 2009-07-09
CL2008003916A1 (es) 2009-09-25
WO2009085981A2 (fr) 2009-07-09
WO2009085981A3 (fr) 2009-08-27

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