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WO2023137259A1 - Renfort en tissu destiné à améliorer la résistance à la flexion d'une plaque en ciment et ses procédés de fabrication - Google Patents

Renfort en tissu destiné à améliorer la résistance à la flexion d'une plaque en ciment et ses procédés de fabrication Download PDF

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Publication number
WO2023137259A1
WO2023137259A1 PCT/US2023/060312 US2023060312W WO2023137259A1 WO 2023137259 A1 WO2023137259 A1 WO 2023137259A1 US 2023060312 W US2023060312 W US 2023060312W WO 2023137259 A1 WO2023137259 A1 WO 2023137259A1
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WIPO (PCT)
Prior art keywords
fabric
coating
cementitious
yarns
fabric reinforcement
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.)
Ceased
Application number
PCT/US2023/060312
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English (en)
Inventor
David R. Blackburn
Jeffrey W. Donelan
Ashish Dubey
Christopher B. TESMER
James B. O'SULLIVAN
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United States Gypsum Co
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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
Priority claimed from US17/937,115 external-priority patent/US20230228085A1/en
Application filed by United States Gypsum Co filed Critical United States Gypsum Co
Priority to CA3242932A priority Critical patent/CA3242932A1/fr
Priority to MX2024007592A priority patent/MX2024007592A/es
Publication of WO2023137259A1 publication Critical patent/WO2023137259A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/07—Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal

Definitions

  • the present invention relates generally to cementitious panels or boards, including cement board and cement fiberboard, wherein the cementitious board is reinforced for tensile strength and impact resistance through use of an improved fabric reinforcement.
  • This invention also relates to coated reinforcing fabrics, and more particularly to alkali-resistant fabric reinforcements for cementitious materials.
  • 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 embedded in the cementitious slurry core.
  • Cementitious boards useful in the construction industry are known to contain inorganic, hydraulically setting material, such as Portland cement or gypsum.
  • Hydraulic gypsum and cement once set, have very little tensile strength and are usually reinforced with facing materials which improve the resistance to tensile and flexural loads. This has been the basis for using paper facing on conventional gypsum wall board and glass fiber scrim in cement boards.
  • Cementitious backerboard comprises a panel having a core layer of lightweight 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 U.S. Pat. No. 3,284,980 P. E. Dinkel, incorporated herein by reference in its entirety.
  • These panels are nailable and can be 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.
  • the facing material is typically a mesh or scrim reinforcing fabric having a yarn count per 2.54 centimeter (1 inch) of the reinforcing fabric that varies from 8x4 to 12x20, for example 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.
  • Cementitious boards have been manufactured by casting a hydraulic cement core mixt in the form of a thin, indefinitely long panel.
  • Cementitious boards 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).
  • a foaming agent as well as other additives can be added to the mix.
  • the hydraulic cement core mix is usually a mortar containing a mixture of water and Portland cement, sand, mineral or non-mineral aggregate, fly ash, accelerators, plasticizers, foaming agents and/or other additives.
  • a strippable paper is deposited on a forming table, then a scrim fed from a roll is deposited on the strippable paper, then a continuous stream of mortar slurry is deposited onto the scrim.
  • the mortar is then distributed across the breadth of the carrier sheet, and the mortar-laden carrier sheet is towed through a slit defined by a supporting surface and a cylindrical mortar screeding roller mounted above the supporting surface so that its axis is transversely parallel to the supporting surface.
  • the long network of reinforcing fibers is drawn against the roller and through the slit, rotating the roller counter to the direction of the travel of the carrier sheet, whereby the roller presses the network into the surface of the mortar and wipes mortar adhering to the roller into the interstices of the network.
  • the network then tows the resulting broad, flat ribbon of mortar towards a cutter.
  • US Patent application publication number 2009/0011207 discloses a fast setting lightweight cementitious composition for construction of cement board or panels.
  • the cementitious composition includes 35-60 wt. % cementitious reactive powder (also termed Portland cement-based binder), 2-10 wt. % expanded and chemically coated perlite filler, 20-40 wt. % water, entrained air, for example 10-50 vol. %, on a wet basis, entrained air, and optional additives such as water reducing agents, chemical set-accelerators, and chemical set- retarders.
  • the lightweight cementitious compositions may also optionally contain 0-25 wt. % secondary fillers, for example 10-25 wt. % secondary fillers.
  • Typical filler include one or more of expanded clay, shale aggregate, and pumice.
  • the cementitious reactive powder used is typically composed of either pure Portland cement or a mixture of Portland cement and a suitable pozzolanic material such as fly ash or blast furnace slag.
  • the cementitious reactive powder may also optionally contain one or more of gypsum (land plaster) and high alumina cement (HAC) added in small dosages to influence setting and hydration characteristics of the binder.
  • the reinforcing fabric most generally employed is a fiber glass scrim and, in particular, is a woven mesh of vinyl coated fiber glass yarns.
  • Glass fiber meshes have been popular as a facing sheet in cement boards because they can increase the dimensional stability in the presence of moisture and provide greater physical and mechanical properties.
  • 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.
  • Most glass fiber compositions, other than AR glass degrade in the alkali environment of a cement core, so they must be coated with a protective finish.
  • US Pat No. 6,054,205 to Newman et al. and related US Pat. No. 6,391 ,131 to Newman et al, both incorporated herein by reference, disclose glass fiber facing sheets comprising an open mesh glass scrim having a plurality of intersecting continuous multifilament yarns. The multifilament yarns are bonded at their crossover points to form a dimensionally stable scrim which can be used to make a cement board with facing sheets mechanically integrated into opposed surface portions of a cementitious core.
  • a conventional method for making the glass fiber facing sheet and a method of making a cement board with this glass facing sheet is disclosed in the related US Pat. No. 6,391 ,131 to Newman et al.
  • US Pat. No. 7,045,474 to Cooper et al. proposed using composite fabric for reinforcement, particularly tensile reinforcement of cementitious boards.
  • mesh constructed from fabric of high modulus strands made from bundles of glass fibers encapsulated by alkali and water resistant thermoplastic material for embedment within the cement matrix to improve tensile strength and impact resistance of the cement board.
  • the reinforcement fabric is disclosed as a woven knit, nonwoven or laid scrim open mesh fabric having mesh openings of a size suitable to permit interfacing between the skin and core cementitious matrix material.
  • the fabric is in a grid-like configuration having a strand count of between about 2 to about 18 strands per inch in the length and width directions.
  • the mesh is preferably composite yarns or rovings of an elastic core strands such as E-glass fibers or similar glass fibers sheathed in a continuous coating of water and alkali resistant material including, sheathed in material.
  • Woven knit and laid scrim fabrics may be coated either:
  • a balanced coating weight distribution is desirable. It is easy to achieve in the case of single-end-coated (SEC) fabrics as each strand is independently and explicitly coated with a given level of coating. The coated strands are then combined into a fabric with the ratio of coating Dry Pick Up (DPUcd/DPUmd) being established simply by selection of yarns containing the desired coating weights-often selected to be the same in MD and CD.
  • SEC single-end-coated
  • US Pat. No. 7,354,876 and US Pat. No. 7,615,504 to Porter et al. incorporated herein by reference propose to achieve balanced coating weight distribution for woven knit and laid scrim fabrics coated either in-line (normally roller or dip coated) or off-line coated after formation.
  • the fabric and reinforcements are which, in a first embodiment, include a plurality of warp yarns having a first twist (turns/inch) and a plurality of weft yarns having a second twist which is greater than the first twist.
  • a coating is applied over a substantial portion of the warp and weft yarns after they are assembled or laid together, so as to produce a weight distribution ratio of less than about 2.0:1 , based upon the weight of the resinous coating of the weft yarns over the weight of the resinous coating on the warp yarns. This can be achieved, in substantial part, due to the difference in the twist ratios of the warp and weft yarns, which difference permits a more uniform coating to be applied.
  • Further embodiments of Porter et al. include a cementitious board and methods of making a coated fabric and cementitious board. [0018] Published application US 2012/0148806 to Dubey et al.
  • a cementitious board system which is reinforced on its opposed surfaces by an improved glass fiber scrim with thicker yarn and larger mesh openings to provide a cementitious board with improved handling properties while retaining tensile strength and long term durability.
  • the fabric is constructed as a mesh of high modulus strands of bundled glass fibers encapsulated by alkali and water resistant material, e.g. a thermoplastic material.
  • the composite fabric also has suitable physical characteristics for embedment within the cement matrix of the panels or boards closely adjacent the opposed faces thereof.
  • the fabric provides a board system with long- lasting, high strength tensile reinforcement and improved handling properties regardless of their spatial orientation during handling.
  • an improved cementitious panel e.g. a cement board reinforced with reinforcing fabric scrim or non-woven fabric layers which provides for more flexural strength and/or peak deflection.
  • the present invention relates to a new and improved scrim (also known as fabric or mesh) useful in an alkaline matrix.
  • the invention also provides a cementitious panel, such as cement board, reinforced with the scrim to have improved flexural strength and/or peak deflection.
  • the bond strength of the intersecting yarns that are woven into a scrim is improved, which in turn improves the tensile and flexural strength of the associated cement board composite.
  • the bond strength of the intersecting yarns of the scrim can be improved either chemically or mechanically or both.
  • the resulting increase in bond strength of the intersecting yarns in turn increases the bond of the scrim (both woven knit and laid scrim fabrics) to the alkaline cementitious matrix in which it is embedded.
  • the inventors theorize that this improvement may increase flexural strength and/or peak deflection of associated cement board composites.
  • the woven knit and laid scrim fabrics of this invention comprise basalt fibers and/or glass fibers.
  • Increasing the chemical and/or mechanical bond of the scrim utilized in a scrim reinforced cementitious panel matrix can be achieved through many possible routes including but not limited to the following examples.
  • Chemical bonding may be increased by applying organic or inorganic adhesives or polymers, such as epoxies, acrylics, styrene acrylics, sodium silicate, or other suitable coatings or bonding materials.
  • Mechanical bonding may be altered by increasing the overall the roughness and/or surface area of the coated yarns of the reinforcing scrim. This may be achieved by embossing or roughening the coating surface, such as the surface of the PVC (polyvinyl chloride) coating commonly used in making the cement board scrims.
  • PVC polyvinyl chloride
  • Improved mechanical bond may also be achieved by bonding various fillers or fibers into or on the scrim coating (example, PVC coating) such as glass fiber, basalt fiber, alkaline resistant fiber, calcium carbonate, quartz, sand, fly ash, perlite, expanded aggregate or other similar materials. Additional weaves that increase surface area or add a third dimension such as a pile or velvet weave may improve mechanical bonding.
  • Chemical bonding may be increased by applying organic or inorganic adhesives or polymers, such as epoxies, acrylics, styrene acrylics, sodium silicate, or other suitable coatings or bonding materials, or other adhesive.
  • the improved mesh made from basalt fiber or fiberglass such as E-glass
  • may be coated with water resistant and alkali resistant coating such as polyvinyl chloride (PVC), epoxies, acrylics, styrene acrylics, or sodium silicate, polyvinyl acetate, polyvinyl alcohol, ethylene vinyl acetate co-polymer, vinyl chlorides, vinyl acrylic copolymer, styrene acrylics, styrene butadiene, polyacrylamide, polyvinyl acrylic, latex emulsions, etc.
  • PVC polyvinyl chloride
  • epoxies acrylics
  • styrene acrylics styrene acrylics
  • sodium silicate sodium silicate
  • polyvinyl acetate polyvinyl alcohol
  • vinyl chlorides vinyl acrylic copolymer
  • styrene acrylics styrene butadiene
  • polyacrylamide polyvinyl acrylic, latex emulsions, etc.
  • Suitable coatings include, without limitation, urea formaldehyde, melamine formaldehyde, stearated melamine formaldehyde, polyester, acrylics, polyvinyl acetate, urea formaldehyde or melamine formaldehyde modified or blended with polyvinyl acetate or acrylic, styrene acrylic polymers, and the like, as well as combinations thereof.
  • the coating may be a latex.
  • polymer latex binders used with or without inorganic filler are, but are not limited to: acrylic latex, Styrene- Butadiene-Rubber (SBR), Styrene-Butadiene-Styrene (SBS), Ethylene-Vinyl-Chloride (EVCI), Poly-Vinylidene-Chloride (PVdC), modified Poly-Vinyl-Chloride (PVC), Poly- Vinyl-Alcohol (PVOH), Ethylene-Vinyl-Actate (EVA), Poly-Vinyl-Acetate (PVA), and Styrene-Acrylate (SA).
  • SBR Styrene- Butadiene-Rubber
  • SBS Styrene-Butadiene-Styrene
  • PVdC Poly-Vinylidene-Chloride
  • PVdC Poly-Vinylidene-Chloride
  • monomers for the coating polymer are butyl acrylate, methyl methacrylate, ethyl acrylate and the like.
  • the monomers include one or more monomers selected from the group consisting of n-butyl acrylate, methyl methacrylate, styrene, and 2-ethylhexyl acrylate.
  • the fabric reinforcement typically includes a plurality of warp yarns having a first twist (turns/inch) and a plurality of weft yarns having a second twist.
  • the fabric further includes a strengthening coating disposed over a substantial portion of the warp and weft yarns.
  • the strengthening coating is a resinous coating that is the binder, such as in the case of a nonwoven scrim, or a finish, such as in the case of a woven or knit scrim.
  • the resinous coating comprises alkali resistant polymer.
  • the woven knit and laid scrim fabrics may be coated by applying organic or inorganic adhesives or polymers, such as epoxies, acrylics, styrene acrylics, sodium silicate, or other suitable coatings or bonding materials, either:
  • the invention can improve the flexural strength of the cement board by strengthening the bond at intersections of the reinforcing yarns such as the fiberglass yarns.
  • the cohesive tensile strength is the resistance to separation of cohesively bonded warp and weft yarns when a tensile force is applied to the either the warp or weft yarns.
  • the invention improves the resistance to failure of intersections which are held together by cohesion, as measured when a tensile force is applied to the fabric.
  • the invention increases cohesive tensile strength at least 10 %, more preferably at least 30 %, further more preferably at least 50%, and most preferably at least 100 %, compared to conventional fiberglass fabrics coated with PVC coatings, wherein the fiberglass yarns typically comprise G75 and/or G37 yarns, and the PVC coating weight typically ranges between 45-65 wt% of the total weight of the fabric.
  • this is typified by the cohesive tensile strength for the improved fabric of this invention typically ranging between 0.15 to 0.60 Ibsf per bonded intersection point of the fabric.
  • the cohesive tensile strength for the coated fiberglass fabric of this invention typically ranging between 0.15 to 0.60 Ibsf per bonded intersection point of the fabric.
  • the cohesive tensile strength of the bonded intersection points of the fabrics of this invention is preferably greater than 0.20 Ibsf, more preferably greater than 0.25 Ibsf, and most preferably greater than 0.30 Ibsf, per bonded intersection point of the fabric.
  • the cohesive tensile strength of the bonded intersection points of the fabrics of this invention is typically at most 0.60 lbs, or at most 0.55 Ibsf, or at most 0.50 Ibsf, per bonded intersection point of the fabric.
  • the yarns are fiberglass yarns or basalt fiber yarns.
  • increased chemical bonding to increase the cohesive tensile strength of the intersection points of the fabric is such that the fabric’s intrinsic tensile strength is realized to increase cement board flexural strength.
  • the fabric “intrinsic tensile strength” relates to the ability of the fabric, via its tensile strength, to provide tensile reinforcement to cement boards.
  • the full potential of this reinforcement is aided by, and can be substantially achieved by, using the present invention, whereas it may not be achieved without the present invention.
  • the invention may increase chemical bonding to increase the cohesive tensile strength of the intersection points of the fabric, preferably such that the fabric’s intrinsic tensile strength is realized, to increase cement board flexural strength with an uncoated scrim modified to improve cement board flexural strength by adhering the strands of scrim together where machine direction and cross-machine strands intersect, for example with cyanoacrylate glue or epoxy.
  • an uncoated scrim modified to improve cement board flexural strength by adhering the strands of scrim together where machine direction and cross-machine strands intersect for example with cyanoacrylate glue or epoxy.
  • US 6,391 ,131 to Newman describe at least one way to do this.
  • the invention can use single end coating or roll coating, similar to how PVC is typically applied to apply the adhesive if the strands are not coated.
  • the invention may alter bond strength of the intersecting yarns of the scrim as well as the corresponding mechanical bond of the scrim to the alkaline cementitious matrix to increase cement board flexural strength with a scrim modified by increasing the overall roughness and/or surface area of the scrim compared to an unmodified scrim.
  • the scrim has a surface roughness value Ra of about 0.1 micron to about 1 .5 micron.
  • Ra is calculated measuring the average of individual measurements of surface heights (peaks) and depths (valleys) across the surface.
  • Ra is described in ASME B46.1 as “the arithmetic average of the absolute values of the profile height deviations from the mean line, recorded within the evaluation length.” This may be achieved by embossing or roughening the coating (example, PVC coating) surface. This may also be achieved by bonding various fillers or fibers into or on the scrim coating surface. Examples of such fillers or fibers include glass fiber, basalt fiber, alkaline resistant fiber, calcium carbonate, quartz, sand, fly ash, perlite, expanded aggregate or other similar materials.
  • this increasing of surface area may be achieved by using scrim that has an alternate weaving pattern.
  • fabrics that add a third dimension such as a pile or velvet weave may improve mechanical bonding.
  • surface area of the fabric is increased at least 20% compared to the conventional PVC coated fiberglass scrims used in manufacturing cement boards, for example, conventional fiberglass scrims coated with PVC coatings, wherein the fiberglass yarns typically comprise G75 and/or G37 yarns, and the PVC coating weight typically ranges between 45-65 wt% of the total weight of the scrim with conventional surface area that ranges from 1 .0 to 1 .05 square inch per square inch planar area of scrim.
  • the enhanced scrim of this invention has a surface area of about 1 .20 to about 2.0 square inch per square inch planar area of scrim.
  • the present invention can, alternatively or cumulatively, employ yarn twist, yarn tension, hydrophilic or hydrophobic coatings, and unbalanced warp-weft constructions, to bring about a more uniform overall coating application to the knit, weave, braid or scrim fabrics.
  • the fabric warp/weft twist level ratio is adjusted between the warp and weft yarns to create directional absorption of the coating so that the "coating weight distribution ratio" changes, for example, such that it is more balanced.
  • the fabric can, for example, be selected from laid scrim, stitch bonding or warp knitting, plain weaving, twill or satin weaving, unidirectional weaving, knitting, and knitting constructions.
  • the typical fabric thickness is about 5-22 mils, with a binder or finish loading of about 18-250 wt. %, based on the weight of the fibers.
  • the warp yarns, weft yarns, or both can include glass filaments totaling 33-400 tex, and are preferably coated by a PVC-based plastisol coating.
  • the warp yarns can be treated with a hydrophilic agent prior to water based coating, or a oleophilic agent, prior to PVC-plastisol coating, and the weft yarns can be treated with an oleophobic agent prior to PVC-plastisol coating or a hydrophobic agent prior to a water based coating, for example.
  • the invention also provides a reinforced cementitious board which includes a cementitious core, such as those including Portland cement or gypsum, and the improved reinforcing scrim (also known as mesh or fabric) disposed on at least one face of the cementitious core.
  • the reinforcing fabric includes a plurality of warp yarns having a first twist (turns/inch) and a plurality of weft yarns having a second twist.
  • a resinous coating is typically applied to the fabric in a "coating weight distribution ratio" of less than about 2.0:1 , based upon the weight percentage of the resinous coating on the weft yarns, over the weight percentage of the resinous coating on the warp yarns ((weft coating weight/weft yarn weight)/(warp coating weight/warp yarn weight)).
  • the improved reinforcing scrim is embedded on or slightly into the cementitious core.
  • the fiberglass mesh or scrim is treated with coating such as a polyvinyl chloride thermal melt coating to resist degradation under alkaline conditions and increase the chemical and/or mechanical bond of the scrim in the cement scrim matrix.
  • coating such as a polyvinyl chloride thermal melt coating to resist degradation under alkaline conditions and increase the chemical and/or mechanical bond of the scrim in the cement scrim matrix.
  • the bottom scrim or mesh layer can be extended over the panel edge and overlap at least a portion of the top mesh or scrim to which it is adhesively attached.
  • FIG. 1 is a perspective view of a cement panel with a scrim layer embedded in the core on the top side of the cement core and, optionally embedded on the opposed side of the core, in accordance with an embodiment of the present invention.
  • FIG. 2 is a front perspective view of a preferred fabric of this invention employing an exemplary plain weave
  • FIG. 3 is an alternative fabric of this invention depicting a five-harness satin weave
  • FIG. 4 is a further embodiment of the fabric of this invention depicting a unidirectional weave
  • FIG. 5 is a further embodiment of the fabric of this invention depicting a fullwidth plain weave with selvage
  • FIG. 6 is a view of the plain weave of FIG. 5 with spacing between yarns labeled.
  • FIG. 7 is a side view of the fabric of FIG. 6.
  • FIG. 8 is a diagram of a non-woven construction pattern for a fiberglass scrim for use in making a reinforced cementitious board of the present invention.
  • FIG. 9 is a diagrammatic side view of an example of a continuous manufacturing line for producing a cementitious board of the invention using an improved scrim fabric.
  • FIG. 10 is a cross-section of the cement panel of this invention with a scrim layer embedded in the core on the top side of the cement core and, optionally embedded on the opposed side of the core.
  • FIG. 11 is a magnified view of a portion of the cementitious board of FIG. 10.
  • FIG. 11 A is a magnified view of the top facing interface of a portion of the cementitious board of FIG. 10.
  • FIG. 12 shows two fibers adhered by adhesive.
  • FIG. 13 is a photograph of a test device used to test cohesive tensile strength in an example.
  • FIG. 14 is a drawing of a test device used to test cohesive tensile strength in an example.
  • Cementitious material An inorganic hydraulically setting material, such as those containing one or more of: hydraulic cement, for example Portland cement, mortar, plaster, gypsum, and/or other ingredients, such as, foaming agents, aggregate, glass fibers, moisture repellants and moisture resistant additives and fire retardants.
  • hydraulic cement for example Portland cement, mortar, plaster, gypsum
  • other ingredients such as, foaming agents, aggregate, glass fibers, moisture repellants and moisture resistant additives and fire retardants.
  • Composite facing material Two or more layers of the same or different materials including two or more layers of fabrics, cloth, knits, mats, wovens, non- wovens and/or scrims, for example.
  • Fabric Woven or non-woven flexible materials, such as tissues, cloth, knits, weaves, carded tissue, spun-bonded, point-bonded, and mesh-type scrim wovens and nonwovens, needled or braided materials.
  • the terms fabric, scrim, and mesh are interchangeably used in this document.
  • Fiber A general term used to refer to filamentary materials. Often, fiber is used synonymously with filament. It is generally accepted that a filament routinely has a finite length that is at least 100 times its diameter. In most cases, it is prepared by drawing from a molten bath, spinning, or by deposition on a substrate. [0059] Filament. The smallest unit of a fibrous material. The basic units formed during drawing and spinning, which are gathered into strands of fiber for use in composites.
  • Glass An inorganic product of fusion that has cooled to a rigid condition without crystallizing. Glass is typically hard and relatively brittle, and has a conchoidal fracture.
  • Glass fiber A fiber spun from an inorganic product of fusion that has cooled to a rigid condition without crystallizing.
  • Knitted fabrics Fabrics produced by interlooping chains of filaments, roving or yarn.
  • Mat A fibrous material consisting of randomly oriented chopped filaments, short fibers, or swirled continuous filaments held together with a binder.
  • Monofilaments are the long continuous single strands which are created by drawing molten glass or basalt as described above.
  • roving the terms “roving”, “yarn”, and “strand” are used interchangeably in this specification to refer to a bundle of monofilaments.
  • Scrim A reinforcing fabric made from continuous filament yarn or strand in an open-mesh construction that can be woven or laid, for example.
  • 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 terms fabric, scrim, and mesh are interchangeably used in this document.
  • Tex Linear density (or gauge) is a unit of measure for the linear mass density of fibers, yarns and thread and is defined as the mass in grams per 1000 meters (g/km). Note that, unless otherwise indicated, any tex values stated for coated fiber is the tex value of the fiber only, without coating.
  • Textile fibers Fibers or filaments that can be processed into yarn or made into a fabric by interlacing in a variety of methods, including weaving, knitting and braiding.
  • Warp The yarn, fiber or roving running longitudinal or lengthwise in a woven, knit or laid or woven scrim fabric through which the weft is woven. A group of yarns, fibers or roving in long lengths and approximately parallel.
  • warp end The particular manner in which a fabric is formed by interlacing yarns, fibers or roving. Usually assigned a style number. Each individual warp thread in a fabric is called a warp end.
  • Woven fabric A material (usually a planar structure) constructed by interlacing yarns, fibers, roving or filaments, to form such fabric patterns as plain, harness satin, or leno weaves, for example.
  • the weft yarn is drawn through the warp yarns to create a fabric.
  • the weft yarn is lateral or transverse relative to the warp yarn.
  • 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
  • Woven roving A heavy glass fiber fabric made by weaving roving or yarn bundles.
  • Yarn One or more fibers or filaments in a group that is handled as an entity as an input in a textile process.
  • the fibers or filaments are either natural or manufactured and form a continuous length that is suitable for use in weaving or interweaving into textile materials, (also known as strand)
  • a roving i.e., a strand of near zero twist with linear densities and filament diameters typical of fiberglass yarn (but substantially without twist)
  • Facing materials, cementitious boards and methods of manufacturing cementitious boards having the facing materials of this invention are provided. Facing materials which are embedded totally, or only partially, so as to present a fibrous facing, are within the scope of this invention.
  • the fabric reinforcements of this invention can be employed in many end-use reinforcement applications, such as, for example, gypsum and cement boards, asphalt and road reinforcement, roofing applications, soil reinforcement, polymer-matrix reinforcement, and as stand-alone coated fabrics in filters, screens and garment applications.
  • FIGS. 1 -6 thereof there is depicted a series of fabrics useful as the facing layer of the facing material of this invention. Needled, woven, knitted, braided and mesh-type nonwoven and composite materials are preferred because of their impressive strength-to-weight ratio and, in the case of wovens, braided, knits, and nonwoven mesh-types (also referred to as "scrim"), their ability to form weft and warp yarn patterns which can be manipulated to create directional absorption of coatings.
  • the facing layers of this invention can contain fibers and filaments of organic and inorganic materials
  • the most preferred fibers contain glass, olefin (such as polyethylene, polystyrene and polypropylene), Kevlar(R), graphite, rayon, polyester, carbon, ceramic fibers, or combinations thereof, such as glass- polyester blends or TWINTEX(R) glass-olefin composite, available from St. Gobain Corporation, France.
  • glass compositions are the most desirable for their fire resistance, low cost and high mechanical strength properties.
  • FIG. 1 schematically shows a perspective view of a cement board 10 having a cement core 12 and scrim wrapped about the core 12.
  • the core layer 12 is made of a cement composition.
  • the reinforcing fiberglass mesh or scrim 32 is embedded in the surface layer of the panel and can be wrapped about the core 12 to form a front layer and a back layer (not shown).
  • the scrim 32 has warp (lengthwise or longitudinal) yarns 32A and weft (lateral or transverse) 32B yarns.
  • the scrim or mesh layer 32 is commonly extended to its edge 21 over the panel edge 19 and overlaps at least a portion of the mesh or scrim 32 on the opposed side and is embedded in the cement core 12.
  • edges 21 of the core layer 12, and end portions of the scrim front layer 22 and front and back layer 32 can be wrapped to produce rounded edge corners. 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.
  • the five main glasses used are high alkali (alkali resistant or AR-glass) useful in motor or cement applications, such as in tile backing, electrical grade (E-glass), a modified E-glass that is chemically resistant (ECR-glass), a modestly chemically resistant glass (C-glass), and high strength (R or S- glass).
  • E-glass electrical grade
  • ECR-glass modified E-glass that is chemically resistant
  • C-glass modestly chemically resistant glass
  • R or S- glass high strength
  • A-glass is also available, but has limited uses.
  • the representative chemical compositions of these five glasses are given in TABLE 1 .
  • the fiberglass strands may be made from E-glass which have typical physical properties listed in TABLE 3.
  • the improved fiberglass mesh used in the present invention may be made from thicker fiberglass yarn such as the DE 37, DE 50, G-50, G-37, H 12, H 25, H 55 and K 18 fiberglass yarns manufactured by PPG, AGY, and Vetrotex, and coated with alkali resistant coating.
  • the filaments designations DE, G, H and K used by the textile industry are listed in TABLE 3A.
  • the different yarns can be mixed and the mesh opening can be non-uniform.
  • the fiberglass yarn in an uncoated state has a nominal linear density of 1200 to 10,000, for example 1200 to 7300, 1200 to 7000, 1200 to 8000, or 1200 to 5000, linear yards per pound of uncoated fiberglass yarn.
  • the fiberglass yarn, in an uncoated state has a nominal density of about 3700 to 5000 linear yards per pound of fiberglass yarn.
  • the coated fibers are typically, 40-80 wt.%, for example 40-65 wt. %, alkali resistant coating on a dry basis with the remainder being the glass fiber itself.
  • TABLE 3A shows mechanical properties of glass yarn.
  • TABLE 4 shows textile fibers designations.
  • the conversion of molten glass in the forehearth into continuous glass fibers is basically an attenuation process.
  • the molten glass flows through a platinum-rhodium alloy bushing with a large number of holes or tips (400 to 8000, in typical production).
  • the bushing is heated electrically, and the heat is controlled very precisely to maintain a constant glass viscosity.
  • the fibers are drawn down and cooled rapidly as they exit the bushing.
  • a sizing is then applied to the surface of the fibers by passing them over an applicator that continually rotates through the sizing bath to maintain a thin film through which the glass filaments pass. After the sizing is applied, the filaments are gathered into a strand before approaching the take-up device.
  • the attenuation rate, and therefore the final filament diameter is controlled by the take-up device. Fiber diameter is also impacted by bushing temperature, glass viscosity, and the pressure head over the bushing.
  • the most widely used take-up device is the forming winder, which employs a rotating collet and a traverse mechanism to distribute the strand in a random manner as the forming package grows in diameter. This facilitates strand removal from the package in subsequent processing steps, such as roving or chopping.
  • the forming packages are dried and transferred to the specific fabrication area for conversion into the finished fiberglass roving, mat, chopped strand, or other product. In recent years, processes have been developed to produce finished roving or chopped products directly during forming, thus leading to the term direct draw roving or direct chopped strand.
  • Basalt is an inert rock found worldwide in abundance as solidified volcanic lava, and is known for its thermal properties, strength, and durability. According to manufacturers, basalt roving delivers exceptional properties when used in woven, nonwoven or chopped form and it has high resistance to corrosion, chemicals, alkaline, acid and solvents. They also claim basalt reinforcements are energy-efficient and lightweight compared to traditional materials such as steel or aluminum and compare favorably to other composite fibers like carbon or fiberglass.
  • Basalt fiber is produced by melting basalt rock and then drawing it into long, continuous filaments which solidify as they cool, similar to fiberglass. The solidified filaments are treated with sizing and twisted together to create continuous basalt fiber.
  • the chemical composition and mechanical properties of basalt fiber can vary significantly. According to Irvine and Baragar’s 1971 paper “A Guide to the Chemical Classification of the Common Volcanic Flocks”, Basalt generally has a composition of 45-52 wt% SiO2, 2-5 wt% total alkalis, 0.5-2.0 wt% TiC , 5-14 wt% FeO and 14 wt% or more AI2O3. Contents of CaO are commonly near 10 wt%, those of MgO commonly in the range 5 to 12 wt%.
  • TABLE 5A and TABLE 5B show properties of typical basalt fiber products.
  • the fabric 10 of the invention can be made in many constructions, such as those shown in FIGS. 1 -8 and can be made by conventional means such woven by plain weaving (FIG. 5, 6, 7), twill or satin weaving (FIGS. 2-3) or unidirectional weaving (FIG. 4) or warp knitting or stitchbonding (not shown).
  • FIG. 8 is a diagram of a non-woven (also known as a laid scrim) construction pattern for a glass fiber or basalt fiber scrim for use in making a reinforced cementitious board of the present invention.
  • Zero twist-yarns may also be used. This input can offer the ease of spreading of (twistless) roving with the coverage of fine-filament yarns.
  • the major characteristics of the knit or woven facing embodiments of this invention include its style or weave pattern, fabric count, and the construction of warp yarn and fill yarn. Together, these characteristics determine fabric properties such as drapability and performance in the final board.
  • the fabric count identifies the number of warp and fill yarns per inch. Warp yarns run parallel to the machine direction, and fill yarns are perpendicular.
  • Woven, knit, braided or mesh-type (scrim) nonwoven fabrics can be coated with water-based resin, oil-based resin or 100% solid coatings to impart strength, provide corrosion or fire resistance, pigmentation and/or other properties.
  • this twist affects the ratio of coating weight in the weft or cross-machine direction versus the coating weight in the warp or machine direction ("coating weight distribution ratio").
  • Coating weight is often measured in the Wet Pick Up (WPU) % or Dry Pick Up (DPU) %, which are the ratios of wet or dry coating weight to yarn weight, respectively.
  • the coating weight distribution ratio is less than about 2.0:1 , and preferably, is less than about 1 .5:1 , with an ideal ratio being about 1 :1 , for example, if all twist is removed from the warp yarns.
  • Plain weave is the simplest form, in which one warp yarn interlaces over and under one fill yarn.
  • Basket weave has two or more warp yarns interlacing over and under two or more fill yarns.
  • Twill weave has one or more warp yarns over at least two fill yarns.
  • Satin weave (crowfoot) consists of one warp yarn interfacing over three and under one fill yarn, to give an irregular pattern in the fabric.
  • the eight harness satin weave is a special case, in which one warp yarn interlaces over seven and under one fill yarn to give an irregular pattern.
  • the satin weave gives the best conformity to complex contours, such as around corners, followed in descending order by twill, basket, and plain weaves.
  • Texturizing is a process in which the textile yarn is subjected to an air jet that impinges on its surface to make the yarn "fluffy".
  • the air jet causes the surface filaments to break at random, giving the yarn a bulkier appearance. The extent to which this occurs can be controlled by the velocity of the air jet and the yarn feed rate. An equivalent effect can be produced by electrostatic or mechanical manipulation of the fibers, yarns or roving.
  • the fabric pattern often called the construction, is an x, y coordinate system.
  • the y-axis represents warp yarns and is the long axis of the fabric roll (typically 30 to 150 m, or 100 to 500 ft.).
  • the x-axis is the fill direction, that is, the roll width (typically 910 to 3050 mm, or 36 to 120 in.).
  • Basic fabrics are few in number, but combinations of different types and sizes of yarns with different warp/f ill counts allow for hundreds of variations.
  • Basic fabric structures include those made by woven, non-woven and knit processes.
  • one preferred design is a knit structure in which both the x axis strands and the y axis strands are held together with a third strand or knitting yarn. This type of knitting is weft-inserted-warp knitting. If an unshifted tricot stitch is used, the s and y axis strands are the least compressed and, therefore, give the best coverage at a given areal weight.
  • This structure's coverage can be further increased, i.e., further reduction in porosity, by using near-zero-twist-yarn or roving which, naturally, spreads more than tightly twisted yarn.
  • This design can be further improved by assisting the spreading of filaments by mechanical (needling) means, or by high-speed air dispersion of the filaments before or after fabric formation.
  • the most common weave construction is the plain weave shown by the fabric 10 in FIG. 2.
  • the essential construction requires only four weaving yarns: two warp yarns 106 and two fill or weft yarns 102.
  • This basic unit is called the pattern repeat.
  • Plain weave which is the most highly interlaced, is therefore the tightest of the basic fabric designs and most resistant to in-plane shear movement.
  • Basket weave a variation of plain weave, has warp and fill yarns that are paired: two up and two down.
  • the satin weave 15 represent a family of constructions with a minimum of interlacing. In these, the weft yarns periodically skip, or float, over several warp yarns, as shown in FIG. 3.
  • the satin weave 15 repeat is x yarns long and the float length is x-1 yarns; that is, there is only one interlacing point per pattern repeat per yarn.
  • the floating yarns that are not being woven into the fabric create considerable loose-ness or suppleness.
  • the satin weave 15 produces a construction with low resistance to shear distortion and is thus easily molded (draped) over common compound curves. Satin weaves can be produced as standard four-, five-, or eight-harness forms. As the number of harnesses increases, so do the float lengths and the degree of looseness making the fabric more difficult to control during handling operations. Textile fabrics generally exhibit greater tensile strength in plain weaves, but greater tear strength in satin weaves.
  • the ultimate mechanical properties are obtained from unidirectional-style fabric 14 (FIG. 4), where the carrier properties essentially vanish when attached to a set cementitious core 101 .
  • a plain weave 16 having glass weft 11 and warp 12 yarns or roving, in a weave construction is known as locking leno, which is used only in special areas of the fabric, such as the selvage, and is woven on a shuttleless loom.
  • FIG. 6 labels the width “w” between yarns and labels diameter “d” of a yarn of a plain weave 16.
  • FIG. 7 shows a side view of the plain weave 16.
  • FIG. 8 is a diagram of a non-woven (also known as a laid scrim) construction pattern for a fiber scrim for use in making a reinforced cementitious board of the present invention.
  • a laid scrim looks like a grid or lattice. It is made from continuous filament products (yarns). In order to keep the yarns in the desired right- angled position it is necessary to join these yarns together. In contrast to woven products the fixation of the warp and weft yarns in laid scrims must be done by chemical bonding.
  • warp yarns are fed from a beam or directly from a creel in the machine direction; this is followed by laying cross yarns (weft yarns) at high speed, alternating above and below the pre-laid warp yarns.
  • the laid scrim is then immediately impregnated and coated with an adhesive coating to ensure the fixation of warp and weft yarns.
  • the coated scrim is then dried and continuously wound on a tube for further processing.
  • conventional fiberglass scrims are replaced with new scrims which are made from fiberglass or basalt fiber strands made in the form of yarns or rovings which are constructed into scrim from bundles of fiberglass or basalt fiber strands.
  • typical fiberglass strands are made from E-glass.
  • Table 4 lists properties of the fiber glass yarns which are used to make both conventional scrim, such as the G75 yarn commercially available AGY Holdings Corp.
  • the invention for example may employ any of a variety of scrim configurations (for example, 8x8, 8x5 and 8x4) in cement board.
  • the scrim used in the present invention can be made from the fiberglass yarn or basalt fiber yarn into scrim having less strands per inch in both the longitudinal (machine) and transverse (cross machine) directions for a mesh with about 4x4 to 6x6, preferably in the range of 4x4 to 5x5 strands per inch, e.g. 4 x 5 or 4.5 x 5.
  • This scrim may also provide more open construction and employ thicker yarns. This produces a reinforced cement board with improved processability, long term durability, field performance, and more uniform distribution of the scrim on the surfaces of the cement board wherein the scrim is embedded in the cementitious slurry before drying of the formed cement board.
  • the yarn used for making the warp and weft can have 0.7Z- 3.0Z twists per inch.
  • the tex values of the yarns used for the G37 is 134 and 99 for the G50 compared to 66 for the G75.
  • the design of fabric 10 suitable for this invention includes fabric parameters: type of fiber, type of yearn, weave style, yarn count, and areal weight.
  • Fiber and scrim manufacturing involves sizing (in some instances also known as binder) and may additionally involve a coating.
  • the sizing is applied to the glass or basalt fibers during yarn manufacture.
  • Sizing is an ultra-thin coating ( ⁇ 1 micron) done during fiber fabrication. This sizing is usually applied in small amounts such as 1 -2.5% by weight of the fiber.
  • a coating may be applied in one or more stages to the scrim and/or to before forming the scrim. For example, a coating may be applied to yarn prior to forming the scrim and then a coating may be applied to the scrim.
  • the total of all coating is preferably applied in an amount from 10 to 80% of the total weight of the coated basalt fiber or fiberglass fabric, more preferably in an amount from 20 to 80%, 20 to 70%, or 20 to 50% of the weight of the coated basalt fiber or fiberglass fabric.
  • a sizing is generally used.
  • Preferred sizings for use with a fibrous layer comprised of basalt or glass filaments include aqueous sizings comprising one of the following blends: 1 ) an epoxy polymer, vinyl and amine coupling agents and a non-ionic surfactant; 2) an epoxy polymer, amine coupling agent and a non-ionic surfactant; 3) an epoxy polymer, methacrylic and epoxy coupling agents, and cationic and non-ionic surfactants (paraffin lubricants); 4) anhydrous polymerized acrylate amine (for example, the substance disclosed in PCT Patent Application No. WO 99/31025, which is incorporated herein by reference), methacrylic and epoxy coupling agents and a non-ionic surfactant; and 5) anhydrous polymerized epoxy amine (for example, as disclosed in U.S. Pat. No.
  • the non-ionic surfactant comprises an organo-silane.
  • sizings are compatible with the preferred coatings for the preferred fabric 10 and the cementitious core 101 , and improve initial fiber strength and ease of fabric forming.
  • the sizings preferably comprise not more than 2.5% by weight, and most preferably less than 1 .5% by weight of the fibrous layer.
  • the coatings are typically also selected from polyvinyl chloride (PVC), polyvinyl alcohol (PVA), polyvinyl acetate (PVAc), polyester, acrylics, acrylonitrile, silane, silicones, styrene-butadiene, polypropylene, polyethylene and epoxy.
  • PVC polyvinyl chloride
  • PVA polyvinyl alcohol
  • PVAc polyvinyl acetate
  • polyester acrylics, acrylonitrile, silane, silicones, styrene-butadiene, polypropylene, polyethylene and epoxy.
  • a coating may be applied to the scrim or to yarn to which the sizing has been applied before forming the scrim (reinforcing fabric).
  • Chemical bonding of the scrim strands (yarns) may increase by applying one or more coatings of organic or inorganic adhesives or polymers, such as epoxies, acrylics, styrene acrylics, sodium silicate, or other suitable coatings or bonding materials, or other adhesive.
  • the improved mesh made from basalt fiber or fiberglass such as E-glass, and may be coated with water resistant and alkali resistant coating such as polyvinyl chloride (PVC), epoxies, acrylics, styrene acrylics, or sodium silicate, polyvinyl acetate, polyvinyl alcohol, ethylene vinyl acetate co-polymer, vinyl chlorides, vinyl acrylic co-polymer, styrene acrylics, styrene butadiene, polyacrylamide, polyvinyl acrylic, latex emulsions, etc.
  • PVC polyvinyl chloride
  • epoxies acrylics
  • acrylicstyrene acrylics styrene acrylics
  • sodium silicate sodium silicate
  • polyvinyl acetate polyvinyl alcohol
  • vinyl chlorides vinyl acrylic co-polymer
  • styrene acrylics styrene butadiene
  • polyacrylamide polyvinyl acrylic, latex emulsions,
  • Suitable coatings include, without limitation, urea formaldehyde, melamine formaldehyde, stearated melamine formaldehyde, polyester, acrylics, polyvinyl acetate, urea formaldehyde or melamine formaldehyde modified or blended with polyvinyl acetate or acrylic, styrene acrylic polymers, and the like, as well as combinations thereof.
  • the coating may be a latex.
  • polymer latex binders used with or without inorganic filler are, but are not limited to: acrylic latex, Styrene-Butadiene-Rubber (SBR), Styrene-Butadiene-Styrene (SBS), Ethylene-Vinyl- Chloride (EVCI), Poly-Vinylidene-Chloride (PVdC), modified Poly-Vinyl-Chloride (PVC), Poly-Vinyl-Alcohol (PVOH), Ethylene-Vinyl-Actate (EVA), Poly-Vinyl-Acetate (PVA), and Styrene-Acrylate (SA).
  • SBR Styrene-Butadiene-Rubber
  • SBS Styrene-Butadiene-Styrene
  • PVdC Poly-Vinylidene-Chloride
  • PVdC Poly-Vinylidene-Ch
  • the coating comprises an alkali resistant coating on the fiberglass fabric that is selected from the group of polyvinyl chloride, polyvinyl alcohol, polyvinyl acetate, polyester, acrylics, acrylonitrile, silicones, styrene-butadiene, polypropylene, epoxy and polyethylene, and mixtures thereof.
  • the coating polymer is preferably derived from at least one acrylic monomer selected from the group consisting of acrylic acid, acrylic acid esters, methacrylic acid, and methacrylic acid esters.
  • the polymer can be a butyl acrylate/methyl methacrylate copolymer or a 2-ethylhexyl acrylate/methyl methacrylate copolymer.
  • the at least one polymer can be a butyl acrylate/methyl methacrylate copolymer or a 2-ethylhexyl acrylate/methyl methacrylate copolymer.
  • the at least one polymer is further derived from one or more monomers selected from the group consisting of styrene, alpha-methyl styrene, vinyl chloride, acrylonitrile, methacrylonitrile, ureido methacrylate, vinyl acetate, vinyl esters of branched tertiary monocarboxylic acids, itaconic acid, crotonic acid, maleic acid, fumaric acid, ethylene, and C4-C8 conjugated dienes such as 1 ,3-butadiene, isoprene or chloroprene.
  • monomers selected from the group consisting of styrene, alpha-methyl styrene, vinyl chloride, acrylonitrile, methacrylonitrile, ureido methacrylate, vinyl acetate, vinyl esters of branched tertiary monocarboxylic acids, itaconic acid, crotonic acid, maleic acid, fumaric acid, ethylene,
  • the coating polymer can be a pure acrylic, a styrene acrylic, a vinyl acrylic or an acrylated ethylene vinyl acetate copolymer.
  • the pure acrylics preferably comprise acrylic acid, methacrylic acid, an acrylate ester, and/or a methacrylate ester as the main monomers).
  • the styrene acrylics preferably comprise styrene and acrylic acid, methacrylic acid, an acrylate ester, and/or a methacrylate ester as the main monomers.
  • the vinyl acrylics preferably comprise vinyl acetate and acrylic acid, methacrylic acid, an acrylate ester, and/or a methacrylate ester as the main monomers.
  • the acrylated ethylene vinyl acetate copolymers preferably comprise ethylene, vinyl acetate and acrylic acid, methacrylic acid, an acrylate ester, and/or a methacrylate ester as the main monomers.
  • the monomers can also include other main monomers such as acrylamide and acrylonitrile, and one or more functional monomers such as itaconic acid and ureido methacrylate, as would be readily understood by those skilled in the art.
  • the film-forming polymer is a pure acrylic such as a butyl acrylate/methyl methacrylate copolymer derived from monomers including butyl acrylate and methyl methacrylate.
  • the coating may be a latex, for example acrylic latex.
  • a latex is a stable dispersion (emulsion) of polymer microparticles in an aqueous medium.
  • polymer latex binders used with the inorganic fillers are, but are not limited to: Styrene- Butadiene-Rubber (SBR), Styrene-Butadiene-Styrene (SBS), Ethylene-Vinyl-Chloride (EVCI), Poly-Vinylidene-Chloride (PVdC), modified Poly-Vinyl-Chloride (PVC), Poly- Vinyl-Alcohol (PVOH), Ethylene-Vinyl-Actate (EVA), Poly-Vinyl-Acetate (PVA), and Styrene-Acrylate (SA).
  • SBR Styrene- Butadiene-Rubber
  • SBS Styrene-Butadiene-Styrene
  • EVCI
  • the coating may comprise polymers derived from versatic acid and/or versatic acid esters as disclosed by US published patent application 2010/0087114 to Bush et al incorporated herein by reference.
  • a suitable latex may also be one comprising carboxylated styrene butadiene (SBR).
  • Synthetic latexes are typically made by emulsion polymerization.
  • Emulsion polymerization is a type of radical polymerization that usually starts with an emulsion incorporating water, monomer, and surfactant.
  • suitable synthetic latexes comprising acrylates are made by polymerizing a monomer such as acrylic acid emulsified with surfactants to make an acrylic latex, preferably an acrylic latex polymer comprised of an acrylic or vinyl ester of a versatic acid isomer.
  • blends such as TWINTEX(R) glass-polyolefin blends produced by Saint-Gobain S.A., or individual multiple layers of polymers, elastomerics, rayon, polyester and glass filaments can be used as roving or yarn for the facing material, or as additional bonded or sewn layers of woven, knitted felt or non-woven layers.
  • a typical coating loading ratio of basalt or glass fiber: coating is about 0.2 to about 2.5 (20-250 wt. %), typically about 0.20 to about 2.0 (20- 200 wt. %) coating on the fabric 10 or reinforcement of this invention.
  • the coating preferably represents the resinous coating 107 of this invention, shown in FIG. 9, and can provide desirable properties, such as strengthening the scrim, stiffening the scrim, slurry penetration resistance, adherence to the core or other layers or materials, hydrophobic or hydrophilic properties, or a combination of these properties.
  • the resinous coating 107 is typically in at least a sufficient amount to bind the fibers and provide finishing properties; in woven or knit scrim embodiments, the resinous coating 107 is typically in at least a sufficient amount to provide finishing properties.
  • additional coating in addition to the amount of coating for binding and/or finishing there may be additional coating in the resinous coating 107.
  • the amounts of coating or binding and/or finishing as well as additional coating, if any, can be used separately or together, and can contain the same or different resinous compositions. Such coatings can enable water vapor, slurry, or both, to pass through the facing during board manufacturing.
  • Such coatings also increase chemical bonding to increase the cohesive tensile strength of the intersection points of the fabric such that the fabric’s intrinsic tensile strength is realized.
  • These coatings may or may not completely coat the exterior facing fibers. In a more preferred embodiment, these coating should virtually completely encapsulate each strand or yarn unless good wetting and penetration allow protection of the large number of interior fibers independent of whether the exterior fibers of the bundle are also encapsulated. In this case some exposed fibers are acceptable to enable attachment.
  • Some exposed fibers enable attachment to factory or field applied coatings or adhesives such as Portland cement based mortar, acrylic adhesive, silicone adhesive and glue on the outer surface of the cementitious board.
  • the selected binders and finishes should also minimize “blocking" (adhesive bonding between adjacent boards during storage).
  • Various coatings are appropriate for this purpose, such as, for example, PVC-based plastisols, phenolic binders, urea formaldehyde resin, or urea formaldehyde resin modified with acrylic, styrene acrylic, with or without carboxylated polymers as part of the molecule, or as a separate additive. Additionally, these coatings can be provided with additives, such as UV and mold inhibitors, fire retardants, etc.
  • Carboxylated polymer additions to the binder resin can promote greater affinity to set gypsum, or to Portland cement-based mortars, for example, but are less subjected to blocking than resins without such additions.
  • One particularly desirable binder resin composition is a 70 wt % urea formaldehyde resin-30 wt % styrene acrylic latex or an acrylic latex mixture, with a carboxylated polymer addition.
  • the coatings for binding and/or finishing can be applied in 1 , 2 or 3 layers or passes.
  • the sizing and the amount of coating for binding and/or finishing there may be additional coating in layer 107 of the same or different composition as the sizing and the coating to finish and/or to bond the fibers together to form the individual layers, as described above, but can be the same or different composition.
  • the additional coating in the resinous coating 107 can include those described in U.S. Pat. No. 4,640,864, which is hereby incorporated by reference, and are preferably water-resistant and/or fire-retardant in nature. They are preferably applied during the manufacture of the fabric 10 of this invention, but may be applied by the board manufacturer prior to use in making cementitious boards.
  • the additional coating in the resinous coating 107 applied to the fabric 100 preferably coats of the warp strands 106 and weft strands 102 of fabric 100.
  • the additional coating in the resinous coating 107 can increase or decrease the wetting angle of the cementitious slurry to reduce penetration or increase adhesion.
  • the coating 107 can further contain a UV stabilizer, mold retardant, alkali-resistant formulation, water repellant, a flame retardant and/or other optional ingredients, such as dispersants, catalysts, fillers and the like.
  • the coating 107 is in liquid form and the fabric 10 is led through the liquid, or the liquid is sprayed (with or without a water spray precursor) on one or both sides of the fabric 100 while the fabric is in tension.
  • Various methods of applying the additional coating 107 may be used, including dip-coaters, doctor blade devices, roll coaters and the like.
  • One preferred method of treating the facing material with the additional coating for the resinous coating 107 of this invention is to have a lower portion of one roll partially submerged in a trough of the liquid resinous composition and the fabric 100 pressed against the upper portion of the same roller so that an amount of the resinous composition is transferred to the fabric 100.
  • the second roller above the first roller controls the movement of the fabric 100 and the uniformity of the amount of additional coating in the resinous coating 107 disposed thereon. Thereafter, the coated fabric 100 is led in a preferred method to steam cans to expedite drying.
  • the coated fabric 100 it is preferred to pass the coated fabric 100 over steam cans at about 250-450° F. (100-200° C.) which drives the water off, if a latex is used, and additionally may cause some flow of the liquid resinous material to coat further and more uniformly fibers within the facer material.
  • the additional coating in the resinous coating 107 preferably covers about 50-80% of the surface area targeted, more preferably about 80-99% of said area.
  • FIG. 8 A common scrim construction of a non-woven scrim is shown in FIG. 8. The first warp thread under a weft thread is followed by a warp thread above the weft thread. This pattern is repeated across the whole width. Two threads will always meet at the intersections.
  • the preferred additional coating of this invention can contain a resinous mixture containing one or more resins.
  • the resin can contain solid particles or fibers which coalesce or melt to form a continuous or semi-continuous coating over and through the yarns.
  • the coating can be applied in various thicknesses, such as for example, to sufficiently cover the fibrous constituents of the fabric 10 so that no fibers protrude from the added coating, or to such a degree that the fibers protrude from the added coating so that they can be used to join to additional layers in a EIF system or to mortar for tile, for example.
  • the additional coating can form an alkali barrier which protects the fabric from alkaline cement cores, for example.
  • the additional coating can comprise a thermoplastic or a thermoset resin.
  • the additional coating can be formed from a mixture of resin and fillers, such as silicates, silica, gypsum, titanium dioxide and calcium carbonate.
  • the additional coating 107 can be applied in latex or curable thermosetting form.
  • Acceptable resins include styrene-acrylic copolymer, acrylics, flame retardant acrylics or brominated monomer additions to acrylic, such as PYROPOLY AC2001 , poly(vinyl acetates), poly(vinyl alcohols), vinylidene chloride, siloxane, and polyvinylchloride such as VYCAR (R) 578.
  • fire retardants such as bromated phosphorous complex, halogenated paraffin, colloidal antimony pentoxide, borax, unexpanded vermiculite, clay, colloidal silica and colloidal aluminum can be added to the resinous coating or saturant.
  • water resistant additives can be added, such as paraffin, and combinations of paraffin and ammonium salt, fluorochemicals designed to impart alcohol and water repellency, such as FC-824 from 3M Co., organo hydrogen polysiloxanes, silicone oil, wax-asphalt emulsions and poly(vinyl alcohol) with or without a minor amount a minor amount of poly(vinyl acetate).
  • the added coating can include pigment, such as kaolin clay, or lamp black thickeners such as modified bentonite clay, defoamers, such as fatty acid/polyglycol mixtures, UV resistance additives, setting accelerators, such as clay compounds, polyacrylamide, potassium salts, or combinations thereof, and dispersants such as sodium polyacrylate.
  • pigment such as kaolin clay, or lamp black thickeners such as modified bentonite clay
  • defoamers such as fatty acid/polyglycol mixtures
  • setting accelerators such as clay compounds, polyacrylamide, potassium salts, or combinations thereof
  • dispersants such as sodium polyacrylate.
  • Known preservatives and, of course, water can be added in latex compositions, and solvents in thermosetting compositions. (See, for example, U.S. Pat. No. 4,640,864, which includes insulation boards including polyvinylchloride based coatings including fire- and water- repellants, and which is hereby incorporated by reference).
  • the preferred fabric 10 and additional coating 107 can provide long term durability in the highly alkaline environment of a cementitious core 101 where the matrix is comprised of materials such as cement paste, mortar, gypsum, concrete and/or geopolymers.
  • the fabric 10 may be comprised of basalt fibers, glass fibers, PVA fibers, carbon fibers, olefin fibers or aramid fibers, for example, or any combination thereof. Most preferably, the fabric 10 contains glass fibers disposed in multifilament yarns.
  • E- glass, AR-glass, A-glass, S-glass or ECR-glass is acceptable.
  • AR-glass is desirable because it has a high degree of resistance to alkali attack and a higher strength retention over time. This is due to the presence of an optimum level of Zirconia (ZrO2), e.g. preferably about 10% to about 25% ZrO2, in the glass fibers.
  • ZrO2 Zirconia
  • This type of glass exhibits a high degree of chemical resistance, resisting the very high alkalinity produced by the hydration of cementitious materials such as ordinary Portland cement.
  • AR-glass has superior strengthening properties necessary for use in earthquake and explosion-resistant applications. It has high tensile strength and modulus and does not rust.
  • Glass fibers may be employed, such as E-glass, ECR- glass, C-glass, S-glass and A-glass, which are not inherently alkali-resistant, but are acceptable when coated with an alkali-resistant material, such as the disclosed polyvinyl chloride resinous coating.
  • the resinous coating 107 as shown in FIG. 11 is preferred where the fibrous layer is comprised of glass; however, coatings are not necessary where the fibrous layer is comprised of AR-glass, PVA, carbon or aramid fibers.
  • the resinous coating 107 desirably provides mechanical and chemical protection to the glass fibrous layers 12.
  • the resinous coating 107 is preferably an acrylate and/or vinyl chloride containing a polymer or polymers, such as acrylic or PVC plastisol, but may be polyvinyl alcohol (PVA), styrene-butadiene rubber (SBR), polyolefin, acrylic acid, unsaturated polyesters, vinyl ester, epoxies, polyacrylates, polyurethanes, polyolefins, phenolics, and the like.
  • PVA polyvinyl alcohol
  • SBR styrene-butadiene rubber
  • polyolefin acrylic acid
  • unsaturated polyesters vinyl ester
  • epoxies polyacrylates
  • polyurethanes polyolefins
  • phenolics phenolics, and the like.
  • the resinous coating comprises alkali resistant polymer.
  • Examples of preferred coatings include an acrylic coating manufactured by Saint-Gobain Technical Fabrics, a Saint-Gobain company, under the label number 534 and a PVC plastisol coating manufactured by Saint-Gobain Technical Fabrics under the label number V38.
  • PVC plastisol as a coating further improves the alkali resistance of the fibrous layer in the inorganic matrix.
  • acrylic as a coating promotes adherence of the fibrous layer to an inorganic matrix, especially where the matrix includes acrylic.
  • the binding, sizing, and/or coating of the fabric 10 are selected or combined to optimize tensile performance and retention of tensile strength after aging, and to improve compatibility between the fibers, sizing, coating and cementitious matrix.
  • the resinous coating 107 could be a sizing having an adherent coating thereon, in which the added cementitious core 101 is adherent to the added coating.
  • a preferred combination includes a sizing selected from the group consisting of 1 ) an epoxy polymer, vinyl and amine coupling agents and a non-ionic surfactant; 2) an epoxy polymer, amine coupling agent and a non-ionic surfactant; 3) an epoxy polymer, methacrylic and epoxy coupling agents, and cationic and non-ionic surfactants (paraffin lubricants); 4) anhydrous polymerized acrylate amine, methacrylic and epoxy coupling agents and a non-ionic surfactant; and 5) anhydrous polymerized epoxy amine, vinyl and amine coupling agents, and a non-ionic surfactant, and a polymeric coating selected from the group consisting of acrylic and PVC plastisol.
  • the woven knit and laid scrim fabrics may be coated by applying organic or inorganic adhesives or polymers, such as epoxies, acrylics, styrene acrylics, or other suitable coatings or bonding materials, before fabric-forming, as in single-end-coated fabrics.
  • organic or inorganic adhesives or polymers such as epoxies, acrylics, styrene acrylics, or other suitable coatings or bonding materials
  • the woven knit and laid scrim fabrics may be coated by applying organic or inorganic adhesives or polymers, such as epoxies, acrylics, styrene acrylics, sodium silicate, or other suitable coatings or bonding materials, after they have been assembled or laid by in-line (normally roller or dip coated) concurrently with formation such as in the case of laid scrim nonwoven meshes.
  • organic or inorganic adhesives or polymers such as epoxies, acrylics, styrene acrylics, sodium silicate, or other suitable coatings or bonding materials
  • the woven knit and laid scrim fabrics may be coated by applying organic or inorganic adhesives or polymers, such as epoxies, acrylics, styrene acrylics, sodium silicate, or other suitable coatings or bonding materials, after they have been assembled or laid by off-line coated after formation (normally roller or dip coated), typically used with many woven fabrics.
  • organic or inorganic adhesives or polymers such as epoxies, acrylics, styrene acrylics, sodium silicate, or other suitable coatings or bonding materials
  • the woven knit and laid scrim fabrics may be uncoated but modified by adhering the strands of scrim together where machine direction and cross-machine strands intersect, for example with cyanoacrylate glue or applying organic or inorganic adhesives or polymers, such as epoxies, acrylics, styrene acrylics, sodium silicate, or other suitable coatings or bonding materials, or other adhesive.
  • FIG. 12 shows two fibers 120, 122 adhered by adhesive 124.
  • US 6,391 ,131 to Newman incorporated herein by reference, describes a method to bond transverse and longitudinal yarns at their crossover points that may be employed for the present invention.
  • the invention can use single end coating or roll coating, similar to how PVC is typically applied to apply the adhesive if the strands are not coated.
  • the transverse yarns and the longitudinal yarns are bonded at their crossover points to provide dimensional stability to the scrim and therefore to the glass fiber facing sheet.
  • the transverse yarns and the longitudinal yarns are bonded at their crossover points by a polymeric binder.
  • the polymeric binder is preferably applied as a low viscosity coating so that it can uniformly penetrate into the transverse yarns and longitudinal yarns and coat the filaments forming the yarns.
  • Numerous different polymeric binders capable of penetrating the transverse yarns and the longitudinal yarns and interlocking the transverse yarns and longitudinal yarns together at their crossover points can be used in the invention.
  • the polymeric binder is an alkali and moisture resistant thermoplastic or thermosetting polymer coating which can, in addition to providing dimensional stability to the scrim, also prevent chemical interaction between the cementitious materials forming the core of the cement board and the glass filamentary material, particularly when an alkaline and/or silicious cementitious material, e.g. Portland cement, is contained in the core of the cement board.
  • an alkaline and/or silicious cementitious material e.g. Portland cement
  • Exemplary moisture resistant materials for the polymeric binder include cyanoacrylate glue, polyvinyl chloride, polyvinyl acetate, polyvinylidene chloride, polyvinyl alcohol, styrene butadiene rubber, urethane, silicone, metallic resinates, wax, asphalt, acrylic resins, styrene acrylate copolymers, aromatic isocyanates and diisocyanates, organo hydrogen polysiloxanes, thermoset resins such as epoxies and phenolics, mixtures thereof, and the like.
  • the preferred polymeric binder for binding the transverse yarns and the longitudinal yarns is polyvinyl chloride (PVC) which is applied as a plastisol.
  • PVC polyvinyl chloride
  • the polymer coating is applied to the scrim in between about 5 and 150 parts dry weight of resin to 100 parts by weight of fabric. In other words, the coating is applied at 5% to 150% dry weight pick-up.
  • the mechanical bond of the intersecting yarns of the scrim and the corresponding mechanical bond of the resulting scrim to the cementitious matrix may be altered by increasing the overall roughness and/or surface area of the coated yarns and/or the resulting scrim. This may be achieved either by embossing or roughening the surface of the coating, such as the PVC coating, or by utilizing different weaving patterns that increase the intersectional bond strength and surface area of the resulting scrim. To be more specific, embossing could be achieved by using an embossing roller in the scrim manufacturing process prior or post drying the PVC coating.
  • various fillers or fibers such as glass fiber, basalt fiber, alkaline resistant fiber, calcium carbonate, quartz, sand, fly ash, perlite, expanded aggregate or other similar materials into or on the scrim coating, for example PVC scrim coating.
  • the invention may increase cement board flexural strength with a scrim modified to improve mechanical bonding by increasing the overall the roughness and/or surface area of the scrim using scrim that has an alternate weaving pattern. Additional weaves that increase surface area or add a third dimension such as a pile or velvet weave may improve mechanical bonding.
  • a typical cement panel 100 of the invention is shown in cross-section in FIG. 10 to reveal a core 101 which extends through the bottom mesh 105 even as the mesh bends up and around to overlap the top mesh 113 which lies just beneath the upper surface of the panel.
  • the cementitious material in the cement panel 100 is an autogenous binder for the lapping meshes 105 and 113 at the margins 76 of the upper surface of the panel.
  • the edges 74 and the margins 76 are smooth because of the smoothing effect of carrier sheet strips being pressed onto the mix by rails and spatulas of a cement panel production line, as for example shown in US Patent 4,916,004 to Ensminger et al.
  • the smooth margins 76 are preferred when the cement panels are fastened side-by-side on a partition and joint tape is adhesively applied to the margins before joint compound is applied.
  • FIG. 10 shows the folded bottom mesh 105 overlying the woven top mesh 113 along the margins, the panel of this invention may be made so that the folded basalt mesh 105 lies under the top mesh 113.
  • the cement panel having the top mesh 113 is described, it will be understood that the top mesh is not essential to this invention.
  • the scrim is typically embedded between about 0.03 to about 0.06 inches into at least one of the planar surface of the cement core layer 101 .
  • a cement panel may have a tendency to be relatively brittle at its edges which often serve as points of attachment for the panels.
  • the edges 74 may be provided with additional mesh reinforcement (not shown) or an alternate reinforcing material, or a combination thereof.
  • the mesh reinforcement can be wrapped around edges 74. The reinforcement is embedded in the cementitious core 101.
  • cementitious boards 100 with facings 105 and 113 which contain fabric 10 can be manufactured in any number of ways, including molding, extrusion, and semi-continuous processes employing rollers and segments of the fabric 10 of this invention.
  • the fabric 10 can be in the form of a facing 105 which can be embedded in the cementitious core 101 , such as to present a thin cementitious film 108 on the face of the board 100.
  • Facing 113 can be embedded, or alternatively, be adhesively or mechanically bonded to the core 101 such as by the set core 101 , itself, as shown in FIG. 11 .
  • FIG. 9 labelled fabric as fabric 10 which is also in FIG. 2 the fabric may be any fabric of the invention.
  • the cementitious board 100 includes a set cementitious core 101 , made of set cement, for example.
  • the cementitious core 101 preferably comprises a cementitious material, such as cement paste, mortar or concrete, and/or other types of materials such as gypsum and geopolymers (inorganic resins).
  • the fibers are AR-glass fibers but may also include, for example, other types of glass fibers, basalt, aramids, polyolefins, carbon, graphite, polyester, PVA, polypropylene, natural fibers, cellulosic fibers, rayon, straw, paper and hybrids thereof.
  • the inorganic matrix may include other ingredients or additives such as fly ash, latex, slag and metakaolin, resins, such as acrylics, polyvinyl acetate, or the like, ceramics, including silicon oxide, titanium oxide, and silicon nitrite, setting accelerators, water and/or fire resistant additives, such as siloxane, borax, fillers, setting retardants, dispersing agents, dyes and colorants, light stabilizers and heat stabilizers, shrinkage reducing admixtures, air entraining agents, setting accelerators, foaming agents, or combinations thereof, for example.
  • the inorganic matrix includes a resin that may form an adhesive bond with a resinous coating applied to the alkali-resistant open fibrous layer.
  • the cementitious core 101 has good bonding with the facings 105 and 113 which contain fabric 10, but also may be composite materials, including additional mats, or scrim of fabrics, for example.
  • the cementitious core 101 may contain curing agents or other additives such as coloring agents, light stabilizers and heat stabilizers, for example.
  • Examples of optional materials which have been reported as being effective for improving the water-resistant properties of cementitious products either as a binder, finish or added coating, or performance additive 103 are the following: poly(vinyl alcohol), with or without a minor amount of poly(vinyl acetate); metallic resinates; wax or asphalt or mixtures thereof; a mixture of wax and/or asphalt and also corn-flower and potassium permanganate; water insoluble thermoplastic organic materials such as petroleum and natural asphalt, coal tar, and thermoplastic synthetic resins such as poly(vinyl acetate), polyvinylchloride and a copolymer of vinyl acetate and vinyl chloride and acrylic resins; a mixture of metal rosin soap, a water soluble alkaline earth metal salt, and residual fuel oil; a mixture of petroleum wax in the form of an emulsion and either residual fuel oil, pine tar or coal tar; a mixture comprising residual fuel oil and rosin, aromatic isocyanates and diisocyanates; organo hydrogen polysi
  • the core may be formed by mixing water with powdered anhydrous calcium sulfate or calcium sulfate hemihydrate (CaSO4 [1/2]H2O), also known as calcined gypsum, and thereafter allowing the mixture to hydrate or set into calcium sulfate dihydrate (CaSO4 «2H2O), a relatively hard material.
  • the cementitious core 101 of the support member will in general comprise at least about 85 wt. % set gypsum or cement.
  • the surface of the cementitious core 101 is faced with one or more layers of the fabric 10.
  • the fabric 10 should be at least sufficiently porous to permit water in the aqueous slurry from which the core is made to evaporate therethrough, and may be porous enough to permit the slurry to pass through and form a continuous or discontinuous film 108.
  • the cementitious board 100 in the present invention can be made efficiently by forming an aqueous slurry which contains excess water and placing thereon the facing material. Aided by heating, excess water evaporates through the preferred upper and lower glass fabric facings 105 or 22 and 116 or 32 as the cementitious slurry 28 sets.
  • cementitious board 100 can be made utilizing existing wallboard or cement board manufacturing lines.
  • Cementitious boards have been manufactured by casting a hydraulic cement core mixture in the form of a thin, indefinitely long panel. Cementitious boards 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). A foaming agent as well as other additives can be added to the mix.
  • 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.
  • the hydraulic cement core mix is usually a mortar containing a mixture of water and Portland cement, sand, mineral or non-mineral aggregate, fly ash, accelerators, plasticizers, foaming agents and/or other additives.
  • a strippable paper (carrier sheet) is deposited on a forming table, then a scrim fed from a roll is deposited on the strippable paper, then a continuous stream of mortar slurry is deposited onto the scrim.
  • the mortar is then distributed across the breadth of the carrier sheet, and the mortar-laden carrier sheet is towed through a slit defined by a supporting surface and a cylindrical mortar screeding roller mounted above the supporting surface so that its axis is transversely parallel to the supporting surface.
  • Water and other liquid constituents (not shown) used in making the core are metered into the mixer 30 where they are combined with the dry ingredients to form an aqueous cementitious slurry 28.
  • Foam is generally added to the cementitious slurry in the mixer 30 to control the density of the resulting cementitious core 101 .
  • the cementitious slurry so produced is then continuously metered and deposited over a continuously moving surface,
  • the said continuously moving surface comprises a glass fabric 22 resting at the bottom and moving at the same speed as the moving surface.
  • the two opposite edge portions of the bottom glass fabric 22 or 105 are progressively flexed upwardly from the mean plane of the bottom glass fabric 22 or 105 and then turned inwardly at the margins so as to provide coverings for the edges of the resulting board 100.
  • a sheet of top glass fabric 32 or 116 is fed from the top glass fabric roll 29 onto the top of the cementitious slurry 28, thereby sandwiching the slurry between the two moving fabrics which form the facings of the cementitious core 101 which is formed from the cementitious slurry 28.
  • the bottom and top glass fabrics 22 (or 105) and 32 (or 116), with the cementitious slurry 28 sandwiched there between enter the nip between the upper and lower forming or shaping rolls 34 and 36 and are thereafter received on a conveyer belt 38.
  • Conventional edge guiding devices 40 shape and maintain the edges of the composite until the slurry has set sufficiently to retain its shape.
  • Water of convenience, or excess water can optionally be drained with the assistance of vacuum boxes 42 disposed below the conveyor belt 38. In due course, sequential lengths of the board are cut by a knife, saw, or any other suitable cutting device 44.
  • the cementitious board 100 is next moved along feeder rolls 46 to permit it to set. It is optionally processed by exposure to heat in a drying oven 48 which accelerates the drying of the board by increasing the rate of evaporation of excess water.
  • An additional sprayer 49 can be provided to add further treatments, such as silicone oil, additional coating, or fire retardants, to the board's exterior.
  • the manufacturing techniques described in the "Background" section are also acceptable.
  • the fabric 10 and cementitious boards 100 of this invention are useful in all sorts of building construction applications. They are strong, having a screw strength of at least about 20 lbs., for gypsum cores of conventional densities and compositions. Some examples include shaft wall assemblies for elevators and stairways, fire doors and fire walls, roofing and siding substrates, with or without insulation, and tile backer boards. Some of the most desirable and useful applications for this invention are in EIF systems (also called EIFS, for Exterior Insulation Finishing Systems), or as tile backer boards.
  • EIF systems also called EIFS, for Exterior Insulation Finishing Systems
  • this invention provides improved coatings and coating techniques for fabrics and reinforcements, and, for example, may enable not only a more uniform coating to be applied to the warp and weft yarns of a knitted, braided, nonwoven mesh-type, or woven fabric but also increased intersectional bond strength between the warp and the weft yarns of the said fabrics. More uniform coatings enable composites, especially those containing cementitious cores, to last longer, achieve better aesthetics, strength and corrosion resistance. The more uniform coatings applied to the reinforcements of this invention can achieve better uniform bonding between glass facings and cement or gypsum cores of boards, as well as better surface finish in cement boards.
  • the more uniform weight distribution of the disclosed coatings permits the boards to achieve greater service life. This can be extended to matrices which must be resistant to fire, rain water and/or salt air.
  • a more uniform coating can also assist the disclosed reinforcements to bond more adherently to a polymer or cementitious matrix and to other yarns having a similar coating in the fabric, as well as assist in bonding to externally applied adhesives, mortars, or the like. Enhanced intersectional bond strength between the warp and the weft yarns of the fabric increases the fabric reinforcing efficiency in a cementitious composite.
  • a fabric reinforcement for reinforcing an alkaline cementitious matrix preferably for improving flexural strength of a cement board made with the alkaline cementitious matrix reinforced with the fabric reinforcement, comprising a plurality of warp yarns and a plurality of weft yarns;
  • the fabric has:
  • the coating comprises organic or inorganic adhesives/polymers, such as polyvinyl chloride (PVC), epoxies, acrylics, styrene acrylics, cyanoacrylate, or sodium silicate, wherein preferably the coating comprises PVC fiber coating of increased weight, and/or the coating has a PVC coating with increased stiffness/strength, or
  • an uncoated scrim modified by adhering the warp yarns and weft yarns together at intersections where warp yarns and weft yarns intersect, for example with organic or inorganic adhesives or polymers, such as cyanoacrylate glue, epoxies, acrylics, styrene acrylics, other suitable bonding materials, or other adhesives; and/or
  • the fabric reinforcement has increased overall roughness and/or surface area relative to a fabric reinforcement having a scrim having respectively relatively lesser overall roughness and/or surface area, preferably such that the fabric reinforcement has overall roughness Ra of about 0.1 microns to about 1 .5 microns.
  • Clause 4 The fabric reinforcement of clause 1 , wherein the fiber resinous coating comprises the PVC coating of increased weight and/or the PVC coating has increased stiffness and/or strength, wherein said PVC coating preferably has a Gurley stiffness of greater than 130 mg/in per ASTM D5732.
  • Clause 8 The fabric reinforcement of clause 1 , the fabric is coated by applying organic or inorganic adhesives or polymers, such as epoxies, acrylics, styrene acrylics, or other suitable coatings or bonding materials, before fabric-forming, typically by coating the yarns, as in single-end-coated fabrics.
  • organic or inorganic adhesives or polymers such as epoxies, acrylics, styrene acrylics, or other suitable coatings or bonding materials
  • the fabric reinforcement of clause 1 may be coated by applying organic or inorganic adhesives or polymers, such as epoxies, acrylics, styrene acrylics, sodium silicate, or other suitable coatings or bonding materials, after they have been assembled or laid by in-line coating (normally roller or dip coated) concurrently with formation such as in the case of laid scrim nonwoven meshes.
  • organic or inorganic adhesives or polymers such as epoxies, acrylics, styrene acrylics, sodium silicate, or other suitable coatings or bonding materials
  • the fabric reinforcement of clause 1 the fabric may be coated by applying organic or inorganic adhesives or polymers, such as epoxies, acrylics, styrene acrylics, or other suitable coatings or bonding materials, after they have been assembled or laid by off-line coating after formation (normally roller or dip coated), typically used with woven fabrics.
  • organic or inorganic adhesives or polymers such as epoxies, acrylics, styrene acrylics, or other suitable coatings or bonding materials
  • the fabric reinforcement of clause 1 the fabric may be uncoated but modified by adhering the warp yarns and weft yarns together where the warp yarns and weft yarns intersect, for example by applying organic or inorganic adhesives or polymers, such as cyanoacrylate glue, epoxies, acrylics, styrene acrylics, or other suitable coatings or bonding materials, or other adhesives.
  • organic or inorganic adhesives or polymers such as cyanoacrylate glue, epoxies, acrylics, styrene acrylics, or other suitable coatings or bonding materials, or other adhesives.
  • the fabric reinforcement comprises glass fiber fabric
  • the coating comprises an alkali resistant coating on the glass fiber fabric that is selected from the group of polyvinyl chloride, polyvinyl alcohol, polyvinyl acetate, polyester, acrylics, acrylonitrile, silicones, styrene-butadiene, polypropylene, epoxy and polyethylene, and mixtures thereof, preferably in an amount from 10 to 70% of the total weight of the coated fiberglass fabric, more preferably in an amount from 20 to 50% of the weight of the coated glass fiber fabric.
  • Clause 15 The fabric reinforcement of clause 1 , wherein the fabric reinforcement is a fiberglass fabric reinforcement having a 8x4, 2x2, 6x6, 6x4, 2x3, or 4.0 x 4.0 strands per inch construction in both the lateral and transverse directions.
  • Clause 16 The fabric reinforcement of clause 1 , wherein the fabric reinforcement is a fiberglass fabric reinforcement having about 3x3 to 6x8 strand per inch construction in the longitudinal and transverse direction, respectively, and wherein the fiberglass fabric reinforcement is made from a coated fiberglass yarn, the yarn in an uncoated state has a nominal density of about 1200 to 10,000 linear yards per pound of fiberglass yarn, for example 1200 to 7000 or 5000 to 8000 linear yards per pound of fiberglass yarn.
  • Clause 17. The fabric reinforcement of clause 1 , wherein the fabric comprises 20 to 80, typically 40 to 80 or 40 to 65, wt. % resinous coating on a dry basis.
  • Clause 18 The fabric reinforcement of clause 1 , wherein the fabric reinforcement has between about 3x3 to about 6x8 strand of fiberglass fiber per inch of the mesh construction in both the longitudinal and transverse directions, respectively, and the fiberglass mesh is made from a coated fiberglass yarn, the yarn in an uncoated state has a nominal density of about 1200 to 8000, for example 3700 to 8000, linear yards per pound of the fiberglass yarn; and the coated yarn comprises 20-80 wt. % coating on a dry basis; the coating comprises alkali resistant polymer.
  • a method of reinforcing a cementitious board comprising providing a core layer of cementitious material, the core layer having opposed planar surfaces and opposed edges, and at least one outer layer of fabric reinforcement embedded within the opposed planar surfaces, comprising: applying the fabric reinforcement of any of clauses 1 -18 to the upper and lower surfaces of a core cementitious slurry by pouring the cementitious slurry through the fabric reinforcement to coat and to embed the entire fabric reinforcement in the cementitious slurry before the slurry is set; wherein the cementitious material comprises:
  • cementitious reactive powder comprising hydraulic cement, for example Portland cement,
  • Clause 21 The cementitious board of clause 20, comprising: a core layer of cementitious material having opposed planar surfaces and opposed edges; at least one outer layer of the fabric reinforcement embedded in the opposed planar surfaces of the core layer; wherein the cementitious material comprises:
  • cementitious reactive powder comprising hydraulic cement, for example comprising Portland cement
  • filler 1 to 70 wt. %, on a wet basis, of filler; optional additive selected from at least one member of the group consisting of water reducing agents, chemical set-accelerators, chemical set- retarders, air-entraining agents, foaming agents, shrinkage control agents, coloring agents, viscosity modifying agents and thickeners, and internal curing agent.
  • optional additive selected from at least one member of the group consisting of water reducing agents, chemical set-accelerators, chemical set- retarders, air-entraining agents, foaming agents, shrinkage control agents, coloring agents, viscosity modifying agents and thickeners, and internal curing agent.
  • Clause 22 The cementitious board of clause 20, wherein the filler is perlite filler, a lightweight aggregate or fillers selected from the group consisting of blast furnace slag, volcanic tuff, pumice, sand, expanded clay, expanded shale, expanded perlite, hollow ceramic spheres, hollow plastic spheres, expanded plastic beads, and mixtures thereof.
  • the filler is perlite filler, a lightweight aggregate or fillers selected from the group consisting of blast furnace slag, volcanic tuff, pumice, sand, expanded clay, expanded shale, expanded perlite, hollow ceramic spheres, hollow plastic spheres, expanded plastic beads, and mixtures thereof.
  • Clause 24 The cementitious board of clause 20, wherein the density of the cement board is about 30 to 100 pounds per cubic foot, typically about 40 to 100 pounds per cubic foot.
  • Typical e-glass fibers used are G75 and G37 which have a lineal weight of approximately 68 and 136 tex, respectively.
  • the first scrim, referred to and an 8x8 consists of eight G75 yarns per inch in the machine direction and eight G75 yarns per inch in the cross-machine direction respective to the weaving machine.
  • a second scrim, referred to as an 8x4 consists of eight G75 yarns per inch in the machine direction and four G37 yarns per inch in the cross-machine direction respective to the weaving machine. It is noted that the overall weight of glass fiber is approximately the same in both scrims.
  • FIG. 14 shows Hydraulic Grip Areas 200, Tape 202, and Tensile Test Direction “T”. Tensile Test Direction “T” of FIG. 14 is also shown as the direction of Force “F” in FIG. 13.
  • the individual lines denote a single yarn
  • the box 202 denotes a heavy adhesive tape applied around the scrim
  • the boxes 200 denote the hydraulic grip areas where samples were gripped for tensile testing.
  • test direction Individual yarns in the test direction were cut as denoted by individual x’s.
  • the hydraulic grip areas are then pulled apart along direction “T” while the pounds-force of this pulling apart is measured.
  • the pounds-force at the point of breakage (fracture) is the cohesive tensile strength.
  • the test is understood to measure the cohesive tensile strength of the intersections with no contribution from glass fiber. Note that slight variations in the dimensions of the test area may be considered to alter the number of yarn intersections being tested. Additionally, samples can be tested in multiple configurations including machine and cross machine direction.
  • the cohesive tensile strength of the three scrims that were tested is shown in the TABLE 18.
  • Intersection cohesive tensile strength is the overall cohesive tensile strength of the fabric.
  • Cohesive tensile strength per bonded intersection point is the overall cohesive tensile strength of the fabric divided by the number of bonded intersection points.
  • the 8x4 scrim for samples listed in TABLE 18 had 96 intersection points.
  • the Cohesive tensile strength per bonded intersection point of about 0.116 Ibf is the Intersection cohesive tensile strength of 11 .1 Ibf divided by 96.
  • TABLE 18 also shows cohesive tensile strength per bonded intersection point of the scrim. It can be observed that for the regular 8x4 scrim (Scrim 2), the cohesive tensile strength was only 0.116 Ibf/bonded intersection point, while the same for the 8x4 scrim of this invention (Scrim 3), the cohesive tensile strength increased substantially to 0.331 Ibf/bonded intersection point.
  • Standard scrim reinforced cementitious lab panels were made with formulations similar to Published US Patent Application number US2012/0148806A1 with a density of 75 pcf.
  • the flexural strength of the samples was tested and shown in the Table 18. The testing showed that a cementitious panel with an 8x8 scrim has 303 psi (39%) higher flexural strength and 0.36 in. (49%) higher maximum deflection than a panel prepared with an 8x4 scrim.
  • a panel was prepared with an 8x4 scrim with cyanoacrylate adhesive, it resulted substantially similar flexural strength and max deflection as the panel prepared with an 8x8 scrim.
  • the following scrims were prepared with an 8x4 scrim from Example 1 (Scrim 2).
  • a scrim (Scrim 4) was prepared by brushing approximately 0.01 Ib/ft2 of RHOPLEX AC 1034 (water-based styrene acrylic polymer emulsion) on the scrim on both sides and allowed to air dry.
  • a second scrim (Scrim 5) was prepared by brushing approximately 0.01 Ib/ft2 of RHOPLEX AC 1034) over the scrim and while the polymer was still wet was dipped into a tray of coarse sand (W540, Black Lab Corp, Serena, IL) adhering approximately 0.06 Ib/ft2 into the polymer material and the composite was allowed to air dry.
  • a third scrim (Scrim 6) was prepared by brushing approximately 0.01 Ib/ft2 of RHOPLEX AC 1034 over the scrim and while the polymer was still wet was dipped into a tray of fine perlite (35-23, Silbrico Corporation, Hodgkins, IL) adhering approximately 0.001 Ib/ft2 into the polymer material and the composite was allowed to air dry.
  • a fourth scrim (Scrim 7) was prepared by brushing approximately 0.01 Ib/ft2 of RHOPLEX AC 1034) over the scrim and while the polymer was still wet was dipped into a tray of 3mm alkali resistant chopped glass fibers (CEM-FIL 70, Owens Corning, Toledo, OH) adhering approximately 0.05 lb/ft 2 into the polymer material and the composite was allowed to air dry.
  • CEM-FIL 70 3mm alkali resistant chopped glass fibers
  • Standard scrim reinforced cementitious lab panels with the same formulation were prepared with a density of approximately 58 pcf.
  • An additional non-woven glass mat with a density of approximately 0.002 Ib/ft2 (RR201 , Unzin, Germany) was laid on the outside surface of the scrim. The flexural strength of the samples was tested and shown in the TABLE 19.

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Abstract

L'invention concerne un renfort en tissu destiné à renforcer une matrice cimentaire alcaline comprenant des fils de chaîne et des fils de trame. Afin d'augmenter la résistance à la traction cohésive de ses points d'intersection, le tissu présente un revêtement suffisamment résineux sur une partie substantielle des fils de chaîne et de trame, avant que le renforcement de tissu ne soit intégré à la matrice cimentaire, ou collé ou lié mécaniquement à celle-ci. Le revêtement comprend des adhésifs/polymères organiques ou inorganiques, ou le tissu présente un tissu non revêtu modifié par adhérence des brins de tissu ensemble, le sens machine et les brins perpendiculaire à la production se croisant, par exemple avec du cyanoacrylate ou de l'époxy. La force de liaison des fils d'intersection du tissu et la résistance de liaison mécanique correspondante du tissu à la matrice cimentaire peuvent également être améliorées par l'augmentation de la rugosité et/ou de la surface des fils et du tissu résultant. L'invention concerne également des procédés de fabrication de tissu, des panneaux cimentaires utilisant le tissu, et des procédés de fabrication du panneau cimentaire.
PCT/US2023/060312 2022-01-14 2023-01-09 Renfort en tissu destiné à améliorer la résistance à la flexion d'une plaque en ciment et ses procédés de fabrication Ceased WO2023137259A1 (fr)

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CA3242932A CA3242932A1 (fr) 2022-01-14 2023-01-09 Renfort en tissu destine a ameliorer la resistance a la flexion d'une plaque en ciment et ses procedes de fabrication
MX2024007592A MX2024007592A (es) 2022-01-14 2023-01-09 Refuerzo de tela para mejorar la resistencia a la flexion de las placas de cemento y metodos para elaborarlo.

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US17/937,115 2022-09-30
US17/937,115 US20230228085A1 (en) 2022-01-14 2022-09-30 Fabric reinforcement for improving cement board flexural strength and methods for making same

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US20230332405A1 (en) * 2020-07-17 2023-10-19 Crt Manufacturing Sdn. Bhd. Reinforcement mesh and method for producing thereof

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