Composite backerboard articles for construction

Abstract

A fabricated article made from two or more discrete sections of a single composite board. The composite board has a planar core with opposing first and second flat sides and a coating of solidified, cement-like mortar disposed on at least one side of the core. The coating has a reinforcement layer disposed therein. Form one or more shapes or cuts in the board that extend through one first side of the core and any coating thereon (with embedded reinforcement layer) and through the second side of the core, but not through the coating and reinforcement layer of the second side. Fabricate the article by bending the two or more discrete sections at the shape or cut and joining them in a fixed position by applying an adhesive to the shape or cut. Alternately, pieces of core, or pieces of core with coating, and, optionally, reinforcement, can be adhesively joined. One can also apply a coating of cement—like mortar, optionally, with an embedded reinforcement to the joined pieces.

What is claimed is:  
     
         1 . An article made from composite board comprising: 
 (A) a substantially planar core having a first flat side and opposite thereto a second flat side,    (B) a coating of solidified, cement-like mortar disposed on the second side or both the first and second sides of the core, and,    (C) embedded within the coating (B) of the second side, and, optionally, the coating of the first side, a reinforcement layer,    where the article comprises two or more discrete sections of composite board produced from a single composite board by forming one or more shapes or cuts in the board which extend through the first side of the core and any coating thereon and through the second side of the core, but not through the coating and reinforcement layer of the second side, the two or more discrete sections being bent at the shape or cut and joined in fixed position by an adhesive applied to the shape or cut.    
     
     
         2 . The article of    claim 1   , wherein the core comprises expanded thermoset or thermoplastic beadboard or extruded foam or fibers, beads, flakes, strips, fragments of organic or inorganic material or both or a combination thereof.  
     
     
         3 . The article of    claim 1   , wherein the core comprises expanded thermoset or thermoplastic beadboard or extruded foam.  
     
     
         4 . The article of    claim 1   , wherein the core comprises extruded thermoplastic foam.  
     
     
         5 . The article of    claim 4   , wherein the core comprises extruded polystyrene foam.  
     
     
         6 . An article made from composite board comprising: 
 (A) a substantially planar core having a first flat side and opposite thereto a second flat side,    (B) a coating of solidified, cement-like mortar disposed on the second side or both the first and second sides of the core, and,    (C) embedded within the coating (B) of the second side, and, optionally, the coating of the first side, a reinforcement layer,    where the article comprises two or more discrete sections of composite board joined by an adhesive at a fixed angle, the discrete sections being pieces of core, or pieces of core with coating (B), and, optionally, with reinforcement (C), and, optionally, a coating (B), optionally, with an embedded reinforcement (C), applied to the joined pieces.    
     
     
         7 . The article of    claim 6   , wherein the article has a coating (B) with an and embedded reinforcement (C) applied to the joined pieces.  
     
     
         8 . The article of    claim 6   , wherein the article has been produced by joining with adhesive pieces of core with coating (B) and reinforcement (C).