Methods for manufacturing cementitious reinforced panels

Abstract

Reinforced facings, including reinforcing webs entrained in hydraulic cement via a slurry bath, adhere to a nailable lightweight aggregate cementitious core to form a panel web. The reinforced web is formed on abutting conveyed carrier sheets, and the web is transversely cut, between the sheets, while moving or when stopped, in response to sensing of the sheets. The cut panels, on respective sheets are stacked for curing without damaging the panel edges and in a manner to minimize panel flex. Slurry bath, facing applicators, and cutter and stacking apparatus are included.

I claim: .[.1. A method for manufacturing cementitious panels of the type having a nailable cementitious aggregate core faced on each major side with a reinforcing element bathed in a slurry comprising hydraulic cement, the method comprising the steps of: 
     
        perpendicular to said uncured panel web and said plane..]. .[.30.  A method as in claim 23 wherein said uncured panel web lies in a substantially horizontal plane and wherein said step of cutting includes drawing a knife cutting edge through and across said uncured panel web, said knife cutting edge being disposed substantially perpendicular to said uncured panel web and said plane..]. .[.31. A method for manufacturing cementitious panels of the type having a nailable cementitious core faced on each major side with a reinforcing element bathed in a slurry comprising hydraulic cement, the method comprising the steps of: running a first elongated indefinite length web of reinforcing material through a slurry bath and depositing said slurry thereto to form a first uncured flexible cementitious element;   metering the amount of slurry deposited on said first web;   dragging an upper surface of said web against a bar to force slurry into said web, while leaving slurry on said upper surface;   depositing cementitious aggregate core material on said uncured flexible cementitious element;   running a second elongated indefinite length web of reinforcing material through a second slurry bath, and depositing slurry thereto to form a second uncured flexible cementitious element;   metering the amount of slurry deposited on said first web;   dragging an upper surface of said web against a bar to force slurry into said web, while leaving slurry on said upper surface;   1aying the second element on said core material;   thereby adhering the elements to respective major sides of said aggregate core material to form an uncured panel web; and thereafter curing said panel..]. .[.32. A method for manufacturing cementitious panels of the type having a nailable cementitious no slump aggregate core faced on each major side with a reinforcing element bathed in a slurry comprising hydraulic cement, the method comprising the steps of:   running an elongated indefinite web of pervious reinforcing mesh material through a slurry bath and depositing an amount of slurry thereto to form a first web uncured flexible cementitious element;   depositing cementitious no slump aggregate core material on said uncured flexible cementitious element;   running a second elongated indefinite length web of pervious reinforcing mesh material through a second slurry bath, and depositing an amount of slurry thereto to form a second wet, uncured flexible cementitious element;   said slurry residing on both sides of said frist and second webs and within interstices of said mesh material;   1aying the second element on said core material;   adhering by the bonding of said slurry the elements to respective major sides of said aggregate core material to form an uncured panel web;   thereafter cutting said uncured panel web to form separate uncured   
     
     
        cementitious panels; and thereafter curing said panels..]. .Iadd.33.  A method for manufacturing a cementitious panel web useful for forming cementitious panels of the type having a nailable cementitious aggregate core faced on each major side with a reinforcing element bathed in a slurry comprising hydraulic cement, the method of forming the web comprising the steps of: running a first elongated indefinite length web of reinforcing material through a slurry bath and depositing said slurry thereto to form a first uncured flexible cementitious element;   metering the amount of slurry deposited on said first web;   dragging an upper surface of said web against a bar to force slurry into said web, while leaving slurry on said upper surface;   depositing cementitious aggregate core material on said uncured flexible cementitious element;   running a second elongated indefinite length web of reinforcing material through a second slurry bath, and depositing slurry thereto to form a second uncured flexible cementitious element;   metering the amount of slurry deposited on said second web;   dragging an upper surface of said second web against a bar to force slurry into said second web, while leaving slurry on said upper surface; and   1aying the second element on said core material;   thereby adhering the elements to respective major sides of said aggregate core material to form an uncured web from which individual panels can be   
     
     
        thereafter formed. .Iaddend. .Iadd.34.  A method for manufacturing a cementitious panel web of the type having a nailable cementitious aggregate core faced on each major side with a reinforcing element bathed in a slurry comprising hydraulic cement, the method of forming the web comprising th steps of: running a first elongated indefinite length web of reinforcing material through a slurry bath and depositing said slurry thereto to form a first uncured flexible cementitious element;   metering the amount of slurry deposited on said first web;   dragging an upper surface of said web against a bar to force slurry into said web, while leaving slurry on said upper surface;   depositing cementitious aggregate core material on said uncured flexible cementitious element;   running a second elongated indefinite length web of reinforcing material through a second slurry bath, and depositing slurry thereto to form a second uncured flexible cementitious element;   metering the amount of slurry deposited on said second web;   dragging an upper surface of said web against a bar to force slurry into said second web, while leaving slurry on said upper surface; and   1aying the second element on said core material;   thereby adhering the elements to respective major sides of said aggregate core material to form an uncured web. .Iaddend.