Fiber-cement/gypsum laminate composite building material

Abstract

Abstract of the Disclosure A 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.

1.  A method for manufacturing a composite building material comprising: 
       applying an adhesive to a face of a gypsum layer; and 
       laminating a fiber cement layer to the adhesive. 
     
     
         2.  The method of claim [ Claim 1 ], wherein the gypsum layer is about ½" thick. 
     
     
         3.  The method of claim [ Claim 1 ], wherein the gypsum layer is a type X fire resistant gypsum board. 
     
     
         4.  The method of claim [ Claim 1 ], wherein the fiber cement layer is about 1/8" thick. 
     
     
         5.  The method of claim [ Claim 1 ], wherein the fiber cement layer is a pre-fabricated fiber cement sheet. 
     
     
         6.  The method of claim [ Claim 1 ], wherein the fiber cement layer comprises cellulose fiber 
       The method of claim [ Claim 1 ], further comprising sanding the fiber cement layer. 
     
     
         7.  The method of claim [ Claim 1 ], wherein the laminating comprises pressing the gypsum layer and fiber cement layer together. 
     
     
         8.  The method of claim [ Claim 1 ], wherein the adhesive is selected from the group consisting of organic adhesives, inorganic adhesives, polyvinyl acetate, water-based polymeric adhesives, solvent-based adhesives, thermoset adhesives, natural polymers, modified starches, liquid moisture cure adhesives, reactive hot melt adhesives, polyurethane, heat or fire resistant adhesives, pressure sensitive adhesives, and combinations thereof. 
     
     
         9.  The method of claim [ Claim 1 ], wherein the adhesive is applied by a roll-coater process. 
     
     
         10.  The method of claim [ Claim 1 ], wherein the adhesive has a wet film thickness of from about 4.5 mil to about 6 mil. 
     
     
         11.  The method of claim [ Claim 1 ], further comprising tapering an edge of the composite building panel. 
     
     
         12.  The method of claim [ Claim 1 ], further comprising sealing the surface of the composite building panel. 
     
     
         13.  The method of claim [ Claim 12 ], wherein at least the fiber cement surface of the composite building panel is sealed with an acrylic sealer. 
     
     
         14.  The method of claim [ Claim 1 ], wherein the composite building material has a fire resistance rating of at least an hour according to ASTM E 119-98.