Method for making wallboard or backerboard sheets including aerated concrete

Abstract

A method for making wallboard or backerboard sheets which are relatively lightweight, strong, and which have good fire resistance, thermal insulation, and sound absorbing properties includes forming core material having opposing first and second major surfaces and comprising aerated concrete, securing at least one face layer on at least one of the first and second major surfaces of the core material, and cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets. The provision of aerated concrete for the core provides many key advantages over conventional gypsum wallboard sheets, and/or conventional backerboard sheets, such as gypsum greenboard or cementitious backerboard, for example. In one class of embodiments, the method may further include curing the core material prior to securing the at least one face layer thereto. In another class, the method may further include curing the core material after securing the at least one face layer thereto.

That which is claimed is:  
     
         1 . A method for making wallboard or backerboard sheets comprising: 
 forming core material having opposing first and second major surfaces and comprising aerated concrete;    securing at least one face layer on at least one of the first and second major surfaces of the core material; and    cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets.    
     
     
         2 . A method according to  claim 1  further comprising curing the core material prior to securing the at least one face layer thereto.  
     
     
         3 . A method according to  claim 1  further comprising curing the core material after securing the at least one face layer thereto.  
     
     
         4 . A method according to  claim 1  wherein forming the core material comprises: 
 dispensing materials for making aerated concrete into a mold and allowing the materials to rise and stiffen into a body;  
 curing the body; and  
 dividing the cured body into a plurality of cured sheets to serve as the core material.  
 
     
     
         5 . A method according to  claim 4  further comprising joining a plurality of the cured sheets together in end-to-end relation while advancing the cured sheets along a path of travel.  
     
     
         6 . A method according to  claim 5  wherein securing the at least one face layer is performed while the cured sheets are advanced along the path of travel.  
     
     
         7 . A method according to  claim 1  wherein forming the core material comprises: 
 dispensing materials for making aerated concrete into a mold and allowing the materials to rise and stiffen into a body;  
 dividing the body into a plurality of uncured sheets; and  
 curing the sheets to serve as the core material.  
 
     
     
         8 . A method according to  claim 7  further comprising joining a plurality of the cured sheets together in end-to-end relation while advancing the cured sheets along a path of travel.  
     
     
         9 . A method according to  claim 8  wherein securing the at least one face layer is performed while the cured sheets are advanced along the path of travel.  
     
     
         10 . A method according to  claim 1  wherein forming the core material comprises: 
 dispensing materials for making aerated concrete into a mold and allowing the materials to rise and stiffen into a body; and  
 dividing the body into a plurality of uncured sheets to serve as the core material.  
 
     
     
         11 . A method according to  claim 10  further comprising curing the uncured sheets after securing the at least one face layer thereto.  
     
     
         12 . A method according to  claim 11  wherein the curing is after cutting.  
     
     
         13 . A method according to  claim 1  wherein forming the core material comprises mixing and dispensing the materials for making aerated concrete in slurry form.  
     
     
         14 . A method according to  claim 13  wherein securing the at least one face layer comprises receiving the aerated concrete in slurry form thereon as the at least one face layer is advanced along a path of travel.  
     
     
         15 . A method according to  claim 14  further comprising: 
 permitting the aerated concrete material to rise and stiffen prior to cutting; and  
 curing the aerated concrete after cutting.  
 
     
     
         16 . A method according to  claim 1  securing the at least one face layer comprises securing first and second face layers on respective first and second major surfaces of the core material.  
     
     
         17 . A method according to  claim 1  wherein the at least one face layer comprises paper.  
     
     
         18 . A method according to  claim 1  wherein the at least one face layer is moisture-resistant.  
     
     
         19 . A method according to  claim 1  further comprising forming the first major surface of the core material to have beveled portions adjacent respective opposing longitudinal side edges.  
     
     
         20 . A method according to  claim 1  wherein securing the at least one face layer comprises securing the at least one face layer to extend around the opposing longitudinal side edges.  
     
     
         21 . A method according to  claim 1  wherein forming the core material comprises forming the core material with reinforcing fibers in the aerated concrete.  
     
     
         22 . A method for making wallboard or backerboard sheets comprising: 
 dispensing materials for making aerated concrete into a mold and allowing the materials to rise and stiffen into a body;    curing the body;    dividing the cured body into a plurality of cured sheets to serve as core material having opposing major surfaces;    securing at least one face layer on at least one of the first and second major surfaces of the core material; and    cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets.    
     
     
         23 . A method according to  claim 22  further comprising joining a plurality of the cured sheets together in end-to-end relation while advancing the cured sheets along a path of travel.  
     
     
         24 . A method according to  claim 23  wherein securing the at least one face layer is performed while the cured sheets are advanced along the path of travel.  
     
     
         25 . A method according to  claim 22  securing the at least one face layer comprises securing first and second face layers on respective first and second major surfaces of the core material.  
     
     
         26 . A method according to  claim 22  wherein the at least one face layer comprises paper.  
     
     
         27 . A method according to  claim 22  wherein the at least one face layer is moisture-resistant.  
     
     
         28 . A method according to  claim 22  further comprising forming the first major surface of the core material to have beveled portions adjacent respective opposing longitudinal side edges.  
     
     
         29 . A method according to  claim 22  wherein securing the at least one face layer comprises securing the at least one face layer to extend around the opposing longitudinal side edges.  
     
     
         30 . A method according to  claim 22  further comprising adding reinforcing fibers to the aerated concrete.  
     
     
         31 . A method for making wallboard or backerboard sheets comprising: 
 dispensing materials for making aerated concrete into a mold and allowing the materials to rise and stiffen into a body;    dividing the body into a plurality of uncured sheets;    curing the uncured sheets to serve as core material having opposing first and second major surfaces;    securing at least one face layer on at least one of the first and second major surfaces of the core material; and    cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets.    
     
     
         32 . A method according to  claim 31  further comprising joining a plurality of the cured sheets together in end-to-end relation while advancing the cured sheets along a path of travel.  
     
     
         33 . A method according to  claim 32  wherein securing the at least one face layer is performed while the cured sheets are advanced along the path of travel.  
     
     
         34 . A method according to  claim 31  securing the at least one face layer comprises securing first and second face layers on respective first and second major surfaces of the core material.  
     
     
         35 . A method according to  claim 31  wherein the at least one face layer comprises paper.  
     
     
         36 . A method according to  claim 31  wherein the at least one face layer is moisture-resistant.  
     
     
         37 . A method according to  claim 31  further comprising forming the first major surface of the core material to have beveled portions adjacent respective opposing longitudinal side edges.  
     
     
         38 . A method according to  claim 31  wherein securing the at least one face layer comprises securing the at least one face layer to extend around the opposing longitudinal side edges.  
     
     
         39 . A method according to  claim 31  further comprising adding reinforcing fibers to the aerated concrete.  
     
     
         40 . A method for making wallboard or backerboard sheets comprising: 
 dispensing materials for making aerated concrete into a mold and allowing the materials to rise and stiffen into a body;    dividing the body into a plurality of uncured sheets having opposing first and second major surfaces to serve as the core material;    securing at least one face layer on at least one of the first and second major surfaces of the core material;    cutting the core material and at least one face layer secured thereto into a plurality of uncured wallboard or backerboard sheets; and    curing the uncured wallboard or backerboard sheets.    
     
     
         41 . A method according to  claim 40  wherein the at least one face layer comprises first and second face layers on respective first and second major surfaces of the core material.  
     
     
         42 . A method according to  claim 40  wherein the at least one face layer comprises paper.  
     
     
         43 . A method according to  claim 40  wherein the at least one face layer is moisture-resistant.  
     
     
         44 . A method according to  claim 40  further comprising forming the first major surface of the core material to have beveled portions adjacent respective opposing longitudinal side edges.  
     
     
         45 . A method according to  claim 40  wherein the at least one face layer extends around the opposing longitudinal side edges.  
     
     
         46 . A method according to  claim 40  further comprising adding reinforcing fibers to the aerated concrete.  
     
     
         47 . A method for making wallboard or backerboard sheets comprising: 
 mixing and dispensing materials for making aerated concrete adjacent at least one face layer advancing along a path of travel;    permitting the aerated concrete materials to rise and stiffen to define core material having first and second opposing surfaces with the at least one face layer secured thereto;    cutting the core material and at least one face layer secured thereto into a plurality of uncured wallboard or backerboard sheets; and    curing the uncured wallboard or backerboard sheets.    
     
     
         48 . A method according to  claim 47  wherein the at least one face layer comprises first and second face layers on respective first and second major surfaces of the core material.  
     
     
         49 . A method according to  claim 47  wherein the at least one face layer comprises paper.  
     
     
         50 . A method according to  claim 47  wherein the at least one face layer is moisture-resistant.  
     
     
         51 . A method according to  claim 47  further comprising forming the first major surface of the core material to have beveled portions adjacent respective opposing longitudinal side edges.  
     
     
         52 . A method according to  claim 47  wherein the at least one face layer extends around the opposing longitudinal side edges.  
     
     
         53 . A method according to  claim 47  further comprising adding reinforcing fibers to the aerated concrete.  
     
     
         54 . A method for making at least one of a wallboard or backerboard sheet comprising: 
 forming a core having opposing first and second major surfaces and at least one face layer thereon, said core comprising aerated concrete.    
     
     
         55 . A method according to  claim 54  wherein the at least one face layer comprises first and second face layers on respective first and second major surfaces of the core.  
     
     
         56 . A method according to  claim 54  wherein the at least one face layer comprises paper.  
     
     
         57 . A method according to  claim 54  wherein the at least one face layer is moisture-resistant.  
     
     
         58 . A method according to  claim 54  wherein the core has a generally rectangular shape defining a pair of opposing side edges and a pair of opposing end edges.  
     
     
         59 . A method according to  claim 58  wherein the first major surface has beveled portions adjacent respective opposing side edges.  
     
     
         60 . A method according to  claim 58  wherein the at least one face layer extends around the opposing side edges.