Fiber-cement/gypsum laminate composite building material

Abstract

Abstract of the DisclosureA building material (40) is provided comprising fiber-cement (10) laminated to gypsum (20) to form a single piece laminate composite. This single piece laminate composite exhibits improved fire resistance and surface abuse and impact resistance, but achieves these properties without the excessive weight and thickness of two piece systems. Additionally, because of the reduced thickness, the preferred laminate building material is easier to cut and is quicker and easier to install than two piece systems. Furthermore, forming the fiber-cement and gypsum into a single piece laminate eliminates the need to install two separate pieces of building material, thereby simplifying installation. In one embodiment, a 5 / 8” thick laminate composite is provided comprising a ½” thick gypsum panel laminated to a 1 / 8” thick fiber-cement sheet, the laminate composite having a fire resistance rating of 1 hour when measured in accordance with ASTM E119.

Description

Detailed Description of the InventionField of the Invention[0001] This invention relates to abuse resistant, impact resistant and fire resistant building materials, and more particularly, to a single piece laminate composite building material of fiber-cement and gypsum.Description of the Related Art[0002] The interior wallboard market has been dominated by the use of gypsum wallboard products for many years. The gypsum wallboard typically comprises thin paper layers wrapped around a gypsum core. For example, one paper layer covers the face and long edges of the board, and the second paper layer usually covers the back surface of the board. The core is predominantly gypsum, and can be modified with additives such as glass fiber, vermiculite and mica to improve fire resistance.[0003] In addition to fire resistance, abuse resistance is another desired quality in wallboards. Gypsum has poor abuse resistance compared to other wallboard materials such as wood or masonry. The paper ...

AI Technical Summary

Benefits of technology

[0007] Accordingly, what is needed is a single piece building material that has good abuse resistance, impact resistance and fire resistance. This building material should also be light, easy to manufacture and compatible with standard building material sizes. With respect to fire resistance, it would be especially advantageous for such a material to have a fire resistance rating of at least one hour as measured by ASTM E119.

[0008] Briefly stated, the needs addressed above are satisfied in one embodiment by a building material comprising fiber-cement laminated to gypsum to form a single piece laminate composite. This single piece laminate composite exhibits improved fire resistance and surface abuse resistance, but achieves these properties without the excessive weight and thickness of two piece systems. Additionally, because of the reduced thickness, the preferred laminate building material is easier to cut and is quicker and easier to install than two piece systems. Furthermore, forming the fiber-cement and gypsum into a single piece laminate eliminates the need to install two separate pieces of building material, thereby simplifying installation.

Problems solved by technology

Gypsum has poor abuse resistance compared to other wallboard materials such as wood or masonry.

The paper surface of gypsum wallboard is easily damaged by impact such as scuffing, indentation, cracking or penetration with hard or soft body objects such as furniture, trolleys, toys, sports equipment and other industrial or residential furnishings.

Such wall abuse is typical in high traffic rooms such as corridors, family living areas, gymnasiums or change rooms.

One disadvantage of fiber cement by itself as a wall panel is that it does not have a fire resistance rating comparable to gypsum wall panels of equal thickness.

Another disadvantage of fiber cement by itself is that it is significantly heavier than gypsum wall panels of equivalent thickness.

This two piece system is disadvantageous because it is significantly heavier than single-layer gypsum wallboards.

Additionally, the 2-layer wallboards require nearly double the amount of labor for installation because two separate wall panels must be installed instead of a single panel.

Also, the extra thickness of the 2-layer systems (5 / 8” + ¼” = 7 / 8”) is not compatible with most door jamb widths.

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