US 12,172,421 B2
Composite building materials and methods of manufacture
Douglas G. Mancosh, Palm Beach Gardens, FL (US); Kevin Line, Brentwood, TN (US); and Darrell J. Turner, Anderson, SC (US)
Assigned to Rise Building Products LLC, Jupiter, FL (US)
Filed by Rise Building Products LLC, Jupiter, FL (US)
Filed on Feb. 6, 2023, as Appl. No. 18/164,893.
Application 18/164,893 is a continuation in part of application No. PCT/US2021/059863, filed on Nov. 18, 2021.
Application PCT/US2021/059863 is a continuation in part of application No. 17/216,858, filed on Mar. 30, 2021, granted, now 11,572,646.
Application 18/164,893 is a continuation in part of application No. 17/216,858, filed on Mar. 30, 2021, granted, now 11,572,646.
Claims priority of provisional application 63/115,318, filed on Nov. 18, 2020.
Prior Publication US 2023/0182435 A1, Jun. 15, 2023
Int. Cl. B32B 5/02 (2006.01); B32B 5/18 (2006.01); B32B 5/24 (2006.01); B32B 29/06 (2006.01)
CPC B32B 5/02 (2013.01) [B32B 5/18 (2013.01); B32B 5/245 (2013.01); B32B 29/06 (2013.01); B32B 2260/021 (2013.01); B32B 2260/028 (2013.01); B32B 2260/046 (2013.01); B32B 2262/101 (2013.01); B32B 2266/0278 (2013.01); B32B 2307/732 (2013.01); B32B 2605/003 (2013.01)] 25 Claims
OG exemplary drawing
 
1. A composite building material, comprising:
a core layer comprising a first binding agent and fibers; and
a top layer disposed above the core layer and comprising a second binding agent and fibers,
wherein the fibers in the core layer and the fibers in the top layer comprise fibers derived from at least one of a scrap fiber source, a used fiber source, a recycled fiber source, or any combination thereof,
wherein at least one of the fibers in the core layer or the fibers in the top layer comprise glass fibers,
wherein the fibers in the top layer have an average length less than about 6 mm and shorter than an average length of the fibers in the core layer,
wherein the first binding agent and the second binding agent each comprises a thermoset cured by applying heat,
wherein the first binding agent and the second binding agent are not foamed,
wherein the core layer and the top layer form a board or a sheet,
wherein the core layer has a substantially nonuniform thickness, the top layer has a substantially nonuniform thickness, and the core layer and the top layer together have a substantially uniform thickness due at least in part to shorter fibers in the top layer filling in valleys and covering thickness irregularities formed by longer fibers in the core layer, and
wherein an average combined thickness of the core layer and the top layer is from about 6 mm to about 40 mm.