US 11,878,486 B2
Building boards with increased surface strength
Robin Daniel Fisher, Loughborough (GB); Devang Umesh Khariwala, Hudson, MA (US); Jeffrey Hamilton Peet, Southborough, MA (US); and Peter Mayer, Tampa, FL (US)
Assigned to CertainTeed Gypsum, Inc., Malvern, PA (US)
Filed by SAINT-GOBAIN PLACO SAS, Suresnes (FR)
Filed on Sep. 6, 2022, as Appl. No. 17/903,263.
Application 17/903,263 is a continuation of application No. 14/583,897, filed on Dec. 29, 2014, granted, now 11,433,645.
Application 14/583,897 is a continuation in part of application No. 14/143,421, filed on Dec. 30, 2013, abandoned.
Application 14/143,421 is a continuation in part of application No. 14/143,338, filed on Dec. 30, 2013, abandoned.
Prior Publication US 2022/0410531 A1, Dec. 29, 2022
This patent is subject to a terminal disclaimer.
Int. Cl. B32B 13/08 (2006.01); E04C 2/04 (2006.01)
CPC B32B 13/08 (2013.01) [E04C 2/043 (2013.01); B32B 2255/12 (2013.01); B32B 2255/26 (2013.01); B32B 2307/54 (2013.01); B32B 2419/00 (2013.01); B32B 2607/00 (2013.01); Y10T 428/24488 (2015.01); Y10T 428/24496 (2015.01); Y10T 428/24612 (2015.01); Y10T 428/249968 (2015.04); Y10T 428/273 (2015.01)] 19 Claims
OG exemplary drawing
1. A composite building board with enhanced nail pull strength, the composite building board comprising:
first and second paper liners each having an interior face, the first paper liner having an exterior face forming an outer face of the building board;
a set plaster core positioned between and bonded with the interior face of the first paper liner and the interior face of the second paper liner, the set plaster core formed from a cementitious slurry of predominantly calcium sulfate hemi-hydrate, the set plaster core being formed with a plurality of internal voids, the internal voids functioning to decrease the overall weight of the building board; and
a spray coating of a coating polymer applied directly to the exterior face of the first paper liner, the spray coating having a tensile modulus above 500 psi and an elongation at break of greater than 500% at room temperature and improving a nail pull strength of the building board relative to an identical building board without the spray coating.