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.

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 com

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 compa

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