Abstract: Methods and a reinforcement fabric are disclosed for making a reinforced smooth cementitious board having a cement skin adjacent to an outer face, by depositing a reinforcement fabric and a layer of hydraulic cementitious material, one on the other, wherein the reinforcement fabric comprises an open mesh united with a thin, porous nonwoven web.

Abstract: A cementitious board and a reinforcement sheet for the board includes, a water vapor porous layer of glass fibers bonded together by a cured binder, and a hydrophilic coating material being mobile in slurry water to wet the binder coated glass fibers and spread a slurry of a cementitious compound, and the hydrophilic coating material being volatile to dissipate by evaporation at an elevated temperature at which the cementitious compound dries to form a dried cementitious board having both the cementitious compound and the binder coated glass fibers essentially free of the hydrophilic coating material.

Abstract: A method of making a reinforcement sheet for a cementitious board includes applying a hydrophilic coating material on binder coated glass fibers, the hydrophilic coating material being mobile in slurry water at a surface of a slurry of a cementitious compound to dilute and disperse, and to wet and spread the slurry on the binder coated glass fibers, and the hydrophilic coating material in the slurry water being volatile to dissipate by evaporation at an elevated temperature at which the cementitious compound is dried for the binder coated glass fibers to be essentially free of the hydrophilic coating material.

Abstract: A method for making a reinforcement material comprises providing at least one strand of carbon fibers. A polyolefin coating is applied. A coating comprising an inner layer of a first polyolefin material and an outer layer of a second polyolefin material may be coextruded on the at least one strand. The first polyolefin material has a substantially lower viscosity than the second polyolefin material at an extrusion temperature of the coextruding step. Alternatively, polyolefin fibers may be core sheath spun on the strands to coat the strands, and the coated strands of carbon fibers formed into a woven or knit fabric or a non-woven mesh for a reinforcing a material.

Abstract: Methods and a reinforcement fabric are disclosed for making a reinforced smooth cementitious board having a cement skin adjacent to an outer face, by depositing a reinforcement fabric and a layer of hydraulic cementitious material, one on the other, wherein the reinforcement fabric comprises an open mesh united with a thin, porous nonwoven web.

Abstract: A cementitious board and a reinforcement sheet for the board includes, a water vapor porous layer of glass fibers bonded together by a cured binder, and a hydrophilic coating material being mobile in slurry water to wet the binder coated glass fibers and spread a slurry of a cementitious compound, and the hydrophilic coating material being volatile to dissipate by evaporation at an elevated temperature at which the cementitious compound dries to form a dried cementitious board having both the cementitious compound and the binder coated glass fibers essentially free of the hydrophilic coating material.

Abstract: A composite fabric for use in reinforcement of cementitious boards and similar prefabricated building wall panels. The fabric includes an open mesh first component of continuously coated, high modulus of elasticity strands and a nonwoven second component fabricated from alkali resistant thermoplastic material. The high modulus strands of the first component are preferably bundled glass fibers encapsulated by alkali and water resistant thermoplastic material. The composite fabric also has suitable physical characteristics for embedment within the cement matrix of the panels or boards closely adjacent the opposed faces thereof. The reinforcement provides long-lasting, high strength tensile reinforcement and impact resistance for the panels or boards. The reinforcement also enables the boards to have smooth outer faces suitable for painting, papering, tiling or other finishing treatment.

Abstract: Fabric and reinforcements are provided by this invention which, in a first embodiment, include a plurality of warp yarns having a first twist (turns/inch) and a plurality of weft yarns having a second twist which is greater than the first twist. A coating is applied over a substantial portion of the warp and weft yarns after they are assembled or laid together, so as to produce a weight distribution ratio of less than about 2.0:1, based upon the weight of the resinous coating of the weft yarns over the weight of the resinous coating on the warp yarns. This can be achieved, in substantial part, due to the difference in the twist ratios of the warp and weft yarns, which difference permits a more uniform coating to be applied. Further embodiments of this invention include a cementitious board and methods of making a coated fabric and cementitious board.

Abstract: A cementitious board and methods of making the same are disclosed by a cementitious board including a cementitious core, a plurality of warp yarns and weft yarns and a coating applied to produce a coating weight distribution ratio of less than about 2.0:1, based upon the weight of the resinous coating of the weft yarns, over the weight of the resinous coating on the warp yarns.

Abstract: A cementitious board and methods of making the same are disclosed by a cementitious board including a cementitious core, a plurality of warp yarns and weft yarns and a coating applied to produce a coating weight distribution ratio of less than about 2.0:1, based upon the weight of the resinous coating of the weft yarns, over the weight of the resinous coating on the warp yarns.

Abstract: The present invention relates to a composite sheet material that is moisture vapor permeable and substantially liquid impermeable, the composite sheet material including as layers a lightweight, non-wet laid polyester nonwoven, a polyurethane breathable film, a polymer-coated, high tenacity polyester mesh, and a lightweight, non-wet laid, polyester nonwoven material. The material is also abrasion, tear, mildew and fire resistant.

Abstract: Fabric and reinforcements are provided by this invention which, in a first embodiment, include a plurality of warp yarns having a first twist (turns/inch) and a plurality of weft yarns having a second twist which is greater than the first twist. A coating is applied over a substantial portion of the warp and weft yarns after they are assembled or laid together, so as to produce a weight distribution ratio of less than about 2.0:1, based upon the weight of the resinous coating of the weft yarns over the weight of the resinous coating on the warp yarns. This can be achieved, in substantial part, due to the difference in the twist ratios of the warp and weft yarns, which difference permits a more uniform coating to be applied. Further embodiments of this invention include a cementitious board and methods of making a coated fabric and cementitious board.

Abstract: This invention provides facing materials for cementitious boards such as those including Portland cement or gypsum cores. The preferred facing material includes, in a first embodiment, a facing layer having an areal weight of about 300 grams/M2, and an air permeability rating of no greater than about 300 CFM/ft2 (FG 436-910 test method). The facing layer reduces the penetration of a slurry of cementitious material during the manufacture of a cementitious board, while permitting the water vapor from the slurry to pass therethrough. The facing materials of this invention can be designed to substantially eliminate the fouling of rolls used in continuous processing of such boards without the use, or with greatly reduced use, of costly viscosity control agents in the slurry.

Abstract: This invention provides facing materials for cementitious boards such as those including Portland cement or gypsum cores. The preferred facing material includes, in a first embodiment, a facing layer having an areal weight of about 300 grams/M2, and an air permeability rating of no greater than about 300 CFM/ft2 (FG 436-910 test method). The facing layer reduces the penetration of a slurry of cementitious material during the manufacture of a cementitious board, while permitting the water vapor from the slurry to pass therethrough. The facing materials of this invention can be designed to substantially eliminate the fouling of rolls used in continuous processing of such boards without the use, or with greatly reduced use, of costly viscosity control agents in the slurry.

Abstract: The present invention relates to a composite sheet material that is water vapor permeable and substantially liquid water impermeable. The composite sheet material includes an outer layer, a film, and a reinforcing layer and, preferably, has an ASTM D3833 water vapor transmission rate of greater than 250 g/m2/day, and a tensile strength of at least about 100 N/5 cm when tested in accordance with ASTM D5035. The sheet material is useful as a membrane for roofing, housewrap, insulation facing and in the fabrication of protective apparel.

Abstract: This invention provides multi-layered composites, laminates and composite joints in which at least one resin-impregnated, fiber-containing layer is joined or laminated to a core layer having a lower flexural modulus or higher elongation at break, higher toughness, or a combination of all or some of these properties. The multi-layer composite produced by laminating or joining these materials together has improved shearout, impact and cutting resistance, since stresses caused by outside forces can be more widely distributed throughout the composite.

Abstract: This invention provides facing materials for cementitious boards such as those including Portland cement or gypsum cores. The preferred facing material includes, in a first embodiment, a facing layer having an areal weight of about 300 grams/M2, and an air permeability rating of no greater than about 300 CFM/ft2 (FG 436-910 test method). The facing layer reduces the penetration of a slurry of cementitious material during the manufacture of a cementitious board, while permitting the water vapor from the slurry to pass therethrough. The facing materials of this invention can be designed to substantially eliminate the fouling of rolls used in continuous processing of such boards without the use, or with greatly reduced use, of costly viscosity control agents in the slurry.

Abstract: A knitted screen cloth fabric including a polymer coated, fiber-reinforced, flexible, foil-like web and method for making same are disclosed, the web including a lattice material of filaments and a polyester binding thread.

Abstract: The present invention relates to a composite sheet material that is water vapor permeable and substantially liquid water impermeable. The composite sheet material includes an outer layer, a film, and a reinforcing layer and, preferably, has an ASTM D3833 water vapor transmission rate of greater than 250 g/m2/day, and a tensile strength of at least about 100 N/5 cm when tested in accordance with ASTM D5035. The sheet material is useful as a membrane for roofing, housewrap, insulation facing and in the fabrication of protective apparel.

Abstract: A knitted screen cloth fabric including a polymer coated, fiber-reinforced, flexible, foil-like web and method for making same are disclosed, the web including a lattice material of filaments and a polyester binding thread.