US4441944A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Building board composition and method of making same
Assignee: MORAMERICA CAPITAL Corp AN IOWA CORP
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Filing: 1981-12-31
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Granted: 1984-04-10
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Expires: 2001-12-31
Abstract
Abstract Novel liquid cementitious slurry coating compositions of portland cement, flyash and polymeric emulsions and optionally containing liquid foam and/or reinforcing fibers are applied to solid cellular monoliths to make weather resistant insulative construction boards and units. The slurry coatings are prepared and applied to the surface(s) of cellular monoliths such as beadboard by roller coating, spraying, or the like, allowed to dry and cure. The density of the coatings can be reduced by foaming of the polymeric emulsion and/or by the incorporation of liquid foam into the slurry mix. Varying surface effects may be impressed on the surface of the damp coating prior to drying and curing to produce building or construction units with high insulation properties, weather resistance, and impact resistance characteristics.
Inventors
- 👤 David H. Massey
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 07:18
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/36; C08J9/365; B; B05; B05D; B05D7/00; B05D7/24; B05D7/26; C04; C04B; C04B28/00; C04B28/02; C04B28/04; C04B38/00; C04B38/10; C09; C09D; C09D5/00; C09D5/18; C04B2111/00; C04B2111/00474; C04B2111/00482; C08J2325/00; C08J2325/02; C08J2325/04; C08J2325/06; Y; Y02; Y02W; Y02W30/00; Y02W30/50; Y02W30/91
Claims Analysis
Total Claims: 8
Claim 1
Independent Claim
91 words
A method of forming an insulative construction monolith which comprises the following: (a) forming a liquid aqueous base cementitious slurry containing from 10 to 70 parts by volume of portland cement, 10 to 70 parts by volume of polymeric emulsion and 10 to 70 parts by volume of flyash containing from 5 to about 100 percent by volume of cenospheres; (b) applying a coating layer of said liquid slurry to at least one surface of a cellular insulating board monolith to form a composite; and (c) drying and curing said composite.
Claim 2
Independent Claim
91 words
A method of forming an insulative construction monolith which comprises the following: (a) forming a liquid aqueous base cementitious slurry containing from 10 to 70 parts by volume of portland cement, 10 to 70 parts by volume of polymeric emulsion and 10 to 70 parts by volume of flyash containing from 5 to about 100 percent by volume of cenospheres; (b) applying a coating layer of said liquid slurry to at least one surface of a cellular insulating board monolith to form a composite; and (c) drying and curing said composite.
Claim 3
Dependent Claim
27 words
A method according to claim 1 which contains from 0 to 80 parts reinforcing fibers selected from the group consisting of fiber glass and organic polymeric fibers.
Claim 4
Dependent Claim
149 words
A method according to claim 1 wherein said slurry is prepared by the following: (a) foaming the polymeric emulsion to produce a foam having a density of from about 2 to 30 lbs/cu. ft. to form a first wet pre-mix; (b) forming a dry pre-mix of the portland cement and flyash and combining the same with the first wet pre-mix; (c) forming a liquid foam pre-mix by foaming from 10 to 30 parts by volume of liquid foaming agent which has been foamed to a volume of 11/2 to 50 times the volume of the unfoamed liquid foaming agent; (d) combining said liquid foam from said step (c) with the combined pre-mixes of step (b) to form a low density coating composition; (e) applying a layer of said coating composition to at least one surface of a solid cellular insulating monolithic element; and (f) drying and curing said composite.
Claim 5
Dependent Claim
15 words
A method according to claim 3 wherein solid cellular insulating monolith is a styrene beadboard.
Claim 6
Dependent Claim
24 words
A method according to claim 3 wherein the coating layer of step (e) is a thickness of from about 1/16 to about 3/4" thick.
Claim 7
Dependent Claim
20 words
A method according to claim 1 wherein the fiber glass reinforcing fibers are in the form of a fiberglass mat.
Claim 8
Dependent Claim
104 words
A method according to claim 1 which comprises the following: (i) applying a thin uniform layer of the liquid cementitious slurry of step (a) to at least one surface of a solid expanded styrene bead monolith; (i) impregnating a fiberglass continuous filament mat with polymeric emulsion and the said impregnated mat to the wet slurry coating applied in step (i) to form a first composite; (iii) applying a second thin uniform layer of the liquid slurry composition of step (a) over the fiberglass mat in the composite formed in step (ii) to form a second composite; and (iv) drying and curing the second composite.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1987-04-10 | 1987-10-10 | 1988-04-10 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-04-10 | 1991-10-10 | 1992-04-10 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-04-10 | 1995-10-10 | 1996-04-10 | $7700.00 | Window Closed / Lapsed |