Composite facer for wallboards

Abstract

A composite facer material for use with cementitious wallboards, where the composite facer is embedded in a top and bottom face thereof. The composite facer material, in a most preferred embodiment, comprises two layers. The first layer is preferably a carded polyester nonwoven mat, which is bonded to a second layer comprising preferably a tri-directional laid scrim fabric reinforcement layer made of continuous glass fibers. The two layers are preferably bonded together using an acrylic adhesive, which offers superior adhesion between the layers as well as superior adhesion between the composite facing material and the cementitious core.

What is claimed is:  
     
         1 . A composite material for use with wallboards, said composite material comprising: 
 a nonwoven mat; and    a reinforcing fabric layer bonded to one side of said nonwoven mat;    wherein said composite material is sufficiently open to allow gypsum slurry to flow therethrough.    
     
     
         2 . The composite material set forth in  claim 1 , wherein said nonwoven mat is made of material selected from the group consisting of polyester, mineral fibers, polyolefin, glass, basalt, polyamides, and any combination thereof.  
     
     
         3 . The composite material set forth in  claim 2 , wherein said polyester nonwoven mat selected from the group consisting of: carded, needlepunched, spunlaced, spunbonded, meltblown, airlaid, hydroentangled and any combination thereof.  
     
     
         4 . The composite material set forth in  claim 1 , wherein said reinforcing fabric layer is made of material selected from the group consisting of mineral fiber, glass, basalt, polyester, polyolefin, polyamides, and any combination thereof.  
     
     
         5 . The composite material set forth in  claim 4 , wherein said glass fabric includes continuous glass yarns.  
     
     
         6 . The composite material set forth in  claim 1 , wherein said mat and said fabric are bonded together using an adhesive selected from the group consisting of polyacrylates, polyvinyl acetate, polyvinyl alcohol, polyvinyl chloride, polyolefin, styrene butadiene rubber, acrylic adhesive, polyvinylidene chloride, and any combination thereof  
     
     
         7 . The composite material set forth in  claim 1 , wherein said mat and said fabric are heat bonded together.  
     
     
         8 . The composite material set forth in  claim 1 , wherein said mat and said fabric are ultrasonically bonded together.  
     
     
         9 . The composite material set forth in  claim 1 , wherein said fabric is selected from the group consisting of woven fabric, knitted fabric, adhesively bonded fabric.  
     
     
         10 . The composite material set forth in  claim 1 , wherein said mat has a weight in the range of 0.25 ounces per square yard and 2.0 ounces per square yard.  
     
     
         11 . The composite material set forth in  claim 10 , wherein said mat has a weight in the range of 0.5 ounces per square yard to 1.5 ounces per square yard.  
     
     
         12 . The composite material set forth in  claim 1 , wherein said reinforcing fabric layer has a yarn density of between 1 thread per inch and 20 threads per inch.  
     
     
         13 . The composite material set forth in  claim 12 , wherein said reinforcing fabric layer has a yarn density of between 4 threads per inch and 10 threads per inch.  
     
     
         14 . The composite material set forth in  claim 1 , wherein yarn size in said reinforcing fabric is in the range between 40 and 4000 denier.  
     
     
         15 . The composite material set forth in  claim 14 , wherein said yarn size in said reinforcing fabric is in the range between 150 and 2000 denier.  
     
     
         16 . The composite material set forth in  claim 15 , wherein said yarn size in said reinforcing fabric is in the range between 220 and 1300 denier.  
     
     
         17 . The composite material set forth in  claim 1 , further comprising a second nonwoven mat attached to said reinforcing fabric, so that said nonwoven mats sandwich said reinforcing fabric therebetween  
     
     
         18 . A method for manufacturing wallboard, said method comprising the steps of: 
 bonding a nonwoven mat to a reinforcing fabric layer to form a composite material;    providing an aqueous cementitious slurry, and bringing said composite material into contact with said slurry; and    allowing said cementitious slurry to flow through and penetrate said composite material to form a continuous film extending over an outer face of said composite material.    
     
     
         19 . The method set forth in  claim 18 , further comprising the step of providing a second layer of composite material, and embedding said second layer of composite material on an opposite side of said cementitious slurry from said first layer of composite material.  
     
     
         20 . The method set forth in  claim 18 , wherein said nonwoven mat is made of material selected from the group consisting of polyester, mineral fiber, polyolefin, glass, basalt, polyamides, and any combination thereof.  
     
     
         21 . The method set forth in  claim 20 , wherein said polyester nonwoven mat is carded.  
     
     
         22 . The method set forth in  claim 18 , wherein said reinforcing fabric layer is made of material selected from the group consisting of glass, mineral fiber, basalt, polyester, polyolefin, polyamides, and any combination thereof.  
     
     
         23 . The method set forth in  claim 22 , wherein said glass fabric includes continuous glass yarns.  
     
     
         24 . The method set forth in  claim 18 , wherein said mat and said fabric are bonded together using an adhesive selected from the group consisting of polyacrylates, polyvinyl acetate, polyvinyl alcohol, polyvinyl chloride, polyolefin, styrene butadiene rubber, acrylic adhesive, polyvinylidene chloride, and any combination thereof  
     
     
         25 . The method set forth in  claim 18 , wherein said mat and said fabric are heat bonded together.  
     
     
         26 . The method set forth in  claim 18 , wherein said mat and said fabric are ultrasonically bonded together.  
     
     
         27 . The method set forth in  claim 18 , wherein said cementitious material is selected from the group consisting of gypsum, concrete, mineral fibers, and any combination thereof.  
     
     
         28 . The method set forth in  claim 18 , wherein said fabric is selected from the group consisting of woven fabric, knitted fabric, and adhesively bonded fabric.  
     
     
         29 . The method set forth in  claim 18 , wherein said reinforcing fabric layer has a yarn density of between 1 thread per inch and 20 threads per inch.  
     
     
         30 . The method set forth in  claim 29 , wherein said reinforcing fabric layer has a yarn density of between 4 threads per inch and 10 threads per inch.  
     
     
         31 . The method set forth in  claim 18 , wherein yarn size in said reinforcing fabric is in the range between 40 and 4000 denier.  
     
     
         32 . The method set forth in  claim 31 , wherein said yarn size in said reinforcing fabric is in the range between 150 and 2000 denier.  
     
     
         33 . The method set forth in  claim 32 , wherein said yarn size in said reinforcing fabric is in the range between 220 and 1300 denier.  
     
     
         34 . The method set forth in  claim 18 , further including the step of orienting the composite material so that said nonwoven mat is facing an outer face of said wallboard, and said reinforcing fabric layer is facing inwardly toward a core of said set cementitious material.