Composite product

Abstract

The Abstract of the Disclosure filed herewith has replaced the previous Abstract of the Disclosure that begins with the words, “A composite product comprising a substrate layer” with the following paragraph: An exemplary composite product and method of manufacturing is provided. In one embodiment, the method includes dewatering a first slurry through a dewatering belt to form a first substrate layer, applying a first functional layer onto at least a portion of the first substrate layer, and dewatering a second slurry through the dewatering belt to form a second substrate layer. A first side of the second substrate layer may be overlayed onto the first functional layer, and the layers may be cured, and the layers bonded.

1 . A method of manufacturing a composite product comprising: applying a first slurry to a dewatering belt; 
 dewatering the first slurry through the dewatering belt to form a first substrate layer;    applying a first functional layer onto at least a portion of the first substrate layer;    applying a second slurry to the dewatering belt;    dewatering the second slurry through the dewatering belt to form a second substrate layer;    overlaying a first side of the second substrate layer onto at least a portion of the first functional layer; and    curing the layers, wherein the first functional layer bonds the first substrate layer and the second substrate layer.    
     
     
         2 . The method of  claim 1 , further comprising positioning a reinforcing layer between the substrate layers.  
     
     
         3 . The method of  claim 2 , wherein the reinforcing layer is a fiber mesh or netting.  
     
     
         4 . The method of  claim 2 , wherein the reinforcing layer is a fiber reinforced cementitious layer.  
     
     
         5 . The method of  claim 4 , wherein the fiber is one or more of polypropylene, glass, polyvinyl alcohol, and cellulose fibers.  
     
     
         6 . The method of  claim 1 , wherein the first substrate layer comprises a mixture of a hydraulic binder, cellulose fibers, and water.  
     
     
         7 . The method of  claim 1 , wherein the first slurry and the second slurry have the same composition.  
     
     
         8 . The method of  claim 1 , wherein the first functional layer comprises a hydraulic binder.  
     
     
         9 . The method of  claim 1 , wherein the first functional layer is provided as a slurry.  
     
     
         10 . The method of  claim 9 , wherein the first functional layer is applied as a slurry.  
     
     
         11 . The method of  claim 9 , wherein the first functional layer has a solids content between about 50 to 90 wt %.  
     
     
         12 . The method of  claim 1 , wherein the first functional layer is formed by spattering.  
     
     
         13 . The method of  claim 1 , further comprising applying a second functional layer onto at least a portion of a side of the second substrate layer.  
     
     
         14 . The method of  claim 1 , wherein the second substrate layer has a second side opposite the first side of the second substrate layer, and further comprising applying a second functional layer onto the second side of the second substrate layer.  
     
     
         15 . The method of  claim 13 , further comprising overlaying a third substrate layer onto at least a portion of the second functional layer.  
     
     
         16 . The method of  claim 1 , wherein the first functional layer is applied by using one or more of a brush, a roller and a knife.  
     
     
         17 . The method of  claim 1 , wherein the first functional layer is applied as a non-continuous layer.  
     
     
         18 . The method of  claim 17 , wherein the first functional layer is a continuous layer after overlaying the second substrate layer onto at least a portion of the first functional layer.  
     
     
         19 . The method of  claim 1 , wherein the first functional layer is an insulating layer.  
     
     
         20 . The method of  claim 1 , wherein the first functional layer is a substantially water impermeable layer.  
     
     
         21 . The method of  claim 1 , wherein curing the layers is performed after overlaying the second substrate layer onto at least a portion of the first functional layer.  
     
     
         22 . A composite product comprising: 
 a plurality of overlaying substrate layers, each bonded to at least one of the plurality of overlaying substrate layers; and    one or more functional layers positioned between two or more of the plurality of overlaying substrate layers wherein the one or more functional layers are configured to improve the bond strength between the two or more of the plurality of overlaying substrate layers than without the one or more functional layers.    
     
     
         23 . The composite product of  claim 22 , wherein the plurality of substrate layers comprise a mixture of a hydraulic binder, cellulose fibers, and water.  
     
     
         24 . The composite product of  claim 22 , wherein the functional layer comprises a hydraulic binder.  
     
     
         25 . The composite product of  claim 24 , wherein the functional layer further comprises a plasticizing agent.  
     
     
         26 . The composite product of  claim 25 , wherein the plasticizing agent comprises one or more of melamine sulphonate formaldehyde condensates, naphthalene sulphonate formaldehyde condensates, naphthalene sulphonates, calcium lignosulphonates, saccharose, sodium gluconate, sulphonic acids, carbohydrates, amino carboxylic acids, polyhydroxycarboxilic acids, melamine formaldehyde sodium bisulphate polymer, condensed sodium salt of sulphonated naphthalene formaldehyde and sulphonated melamine.  
     
     
         27 . The composite product of  claim 25 , wherein the plasticizing agent is between about 0.3 to 3 wt % based on total of dry ingredients.  
     
     
         28 . The composite product of  claim 24 , wherein the functional layer further comprises a filler.  
     
     
         29 . The composite product of  claim 28 , wherein the filler comprises one or more of fly ash, hollow microspheres, sand, diatomite, wollastonite, ground rice hulls, ground perlite, calcium carbonate and alumina hydrate.  
     
     
         30 . The composite product of  claim 28 , wherein the filler is between about 5 to 30 wt % based on total of dry ingredients.  
     
     
         31 . The composite product of  claim 24 , wherein the functional layer further comprises latex.  
     
     
         32 . The composite product of  claim 24 , wherein the functional layer further comprises vinyl polymer.  
     
     
         33 . The composite product of  claim 22 , wherein the functional layer is a reinforcing layer.  
     
     
         34 . The composite product of  claim 33 , wherein the functional layer is a fiber mesh or netting.  
     
     
         35 . The composite product of  claim 22 , wherein the functional layer is an insulating layer.  
     
     
         36 . The composite product of  claim 22 , wherein the functional layer is a substantially water impermeable layer.  
     
     
         37 . The composite product of  claim 22 , wherein the functional layer is an adhesive.  
     
     
         38 . The composite product of  claim 22 , wherein the functional layer provides added tensile strength to the composite product.  
     
     
         39 . A method for improving bond strength of a laminated product comprising: 
 providing a first cementitious substrate layer;    disposing a second cementitious substrate layer onto the first substrate layer; and    providing a functional layer between the substrate layers prior to the layers being cured.    
     
     
         40 . The method of  claim 39 , further comprising curing the layers in an autoclave.  
     
     
         41 . The method of  claim 39 , wherein the substrate layer comprises a mixture of hydraulic binder, cellulose fibers and water.  
     
     
         42 . The method of  claim 39 , wherein the functional layer is a slurry comprising a hydraulic binder and a dewatering agent.  
     
     
         43 . The method of  claim 39 , wherein the functional layer is configured to chemically bond with hydroxyl groups of the fibers of the cementitious substrate layers.  
     
     
         44 . The method of  claim 42 , wherein the functional layer has a solids content between about 50 to 90 wt %.  
     
     
         45 . The method of  claim 39 , wherein the functional layer is applied as a non-continuous layer.  
     
     
         46 . The method of  claim 39 , wherein providing the functional layer is performed by spattering.  
     
     
         47 . The method of  claim 39 , wherein providing the functional layer is performed by spraying.  
     
     
         48 . The method of  claim 39 , wherein providing the functional layer is performed by using one or more of a brush, a roller and a knife.