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A building material is provided in which fiber-cement is laminated to gypsum to form a single piece laminate composite. This single piece laminate composite exhibits improved fire resistance and surface abuse and impact resistance, but achieves these properties without the excessive weight and thick

A building material is provided in which fiber-cement is laminated to gypsum to form a single piece laminate composite. This single piece laminate composite exhibits improved fire resistance and surface abuse and impact resistance, but achieves these properties without the excessive weight and thickness of two piece systems. Additionally, because of the reduced thickness, the preferred laminate building material is easier to cut and is quicker and easier to install than two piece systems. Furthermore, forming the fiber-cement and gypsum into a single piece laminate eliminates the need to install two separate pieces of building material, thereby simplifying installation. In one embodiment, a 5/8" thick laminate composite is provided in which a 1/2" thick gypsum panel laminated to a 1/8" thick fiber-cement sheet, the laminate composite having a fire resistance rating of 1 hour when measured in accordance with ASTM E119-98.

대표청구항 ▼

1. A building material comprising: a pre-fabricated fiber-cement sheet; a gypsum panel; and an adhesive layer wherein the adhesive layer is not integral to the pre-fabricated fiber-cement sheet, wherein the adhesive layer is interposed between the fiber-cement sheet and the gypsum panel, wherei

1. A building material comprising: a pre-fabricated fiber-cement sheet; a gypsum panel; and an adhesive layer wherein the adhesive layer is not integral to the pre-fabricated fiber-cement sheet, wherein the adhesive layer is interposed between the fiber-cement sheet and the gypsum panel, wherein the fiber-cement sheet is laminated to the gypsum panel with the adhesive layer to form a single piece laminate composite having a fire resistance rating of at least one hour according to ASTM E 119-98. 2. The building material of claim 1, wherein the adhesive layer comprises polyvinyl acetate. 3. The building material of claim 1, wherein the adhesive layer comprises material selected from the group consisting of water-based polymeric adhesives, solvent-based adhesives, thermoset adhesives, natural polymers such as modified starches, liquid moisture cure or reactive hot melt adhesives such as polyurethane, heat or fire resistant adhesives, and any combinations thereof. 4. The building material of claim 1, wherein the adhesive layer is between about 4.5 mils and 6 mils thick. 5. The building material of claim 1, wherein the building material has a thickness of about 5/8 inch. 6. The building material of claim 1, wherein the pre-fabricated fiber-cement panel contains cellulose fibers. 7. A building material, comprising: a fiber-cement layer containing cellulose fibers; and a gypsum layer, wherein the gypsum layer is laminated to the fiber cement layer for form a single piece laminate composite. 8. The building material of claim 7, wherein the single piece laminate composite has a fire resistance rating greater than that of either the fiber-cement layer or the gypsum layer individually. 9. The building material of claim 7, wherein the single piece laminate composite has a thickness of about 5/8 inch. 10. The building material of claim 9, wherein the fiber-cement layer has a thickness of about 1/8 inch. 11. The building material of claim 9, wherein the gypsum layer has a thickness of about 1/2 inch. 12. The building material of claim 7, wherein the fiber-cement layer is laminated to the gypsum layer with a discrete adhesive layer that is not integrally formed as part of the fiber-cement layer, wherein the adhesive layer is applied to the fiber-cement layer after the fiber-cement layer is formed. 13. The building material of claim 12, wherein the fiber-cement layer is laminated to the gypsum layer with an adhesive that is between about 4.5 mil and 6 mil thick. 14. The building material of claim 7, wherein the fiber-cement layer has a thickness such that the fiber-cement layer individually is not self supporting. 15. A building material, comprising: a pre-fabricated fiber-cement panel; and a gypsum panel, wherein the gypsum panel is laminated to the pre-fabricated fiber-cement panel to form a single piece laminate composite. 16. The building material of claim 15, wherein the building material has a thickness of about 5/8 inch. 17. The building material of claim 15, wherein the pre-fabricated fiber-cement panel contains cellulose fibers. 18. The building material of claim 15, wherein the pre-fabricated fiber-cement panel has a density of up to 2.0 g/cm3. 19. The building material of claim 15, wherein the single piece laminate composite has a fire resistance rating of at least one hour according to ASTM E 119-98. 20. The building material of claim 15, wherein the pre-fabricated fiber cement panel and the gypsum panel are laminated to each other using an adhesive.