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Lightweight, fiber reinforced, cementitious panels possessing exceptional toughness for use as building components in applications such as roofing elements, siding elements, framing and sheathing elements, and substrate elements for installation of floor finishes in residential and other building co

Lightweight, fiber reinforced, cementitious panels possessing exceptional toughness for use as building components in applications such as roofing elements, siding elements, framing and sheathing elements, and substrate elements for installation of floor finishes in residential and other building construction types. The panels employ a continuous phase resulting from the curing of an aqueous mixture of inorganic binder, PVA fibers and lightweight filler. The inorganic binder may be, for example, hydraulic cement alone, or a combination of hydraulic cement and pozzolan/s, or a combination of hydraulic cement, alpha hemihydrate, active pozzolan and optionally lime. The PVA fibers reinforce the continuous phase and are randomly distributed throughout the composite. Typical panels of the invention have a density of 60-85 pcf.

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What is claimed is: 1. A reinforced, lightweight, dimensionally stable building panel having a density of 60-85 pcf (961-1360 kg/m3) and a flexural strength of about 750 to 1180 psi consisting essentially of: a continuous phase resulting from the curing of an aqueous mixture of a cementitious compo

What is claimed is: 1. A reinforced, lightweight, dimensionally stable building panel having a density of 60-85 pcf (961-1360 kg/m3) and a flexural strength of about 750 to 1180 psi consisting essentially of: a continuous phase resulting from the curing of an aqueous mixture of a cementitious composition, the cementitious composition consisting essentially of, on a dry basis, 35-70 wt. % reactive powder, 20-50 weight % lightweight filler, 0 weight % glass fibers, and 0.5-5.0 weight % polyvinyl alcohol fibers, the continuous phase being reinforced with the polyvinyl alcohol fibers and containing the lightweight filler having a particle specific gravity of from 0.02 to 1.00 and a mean particle diameter size from 50 to 250 microns and/or fall within a particle diameter size range of 10 to 500 microns, wherein the reactive powder comprises, on a dry basis, 35 to 75 wt. % calcium sulfate alpha hemihydrate, 20 to 55 wt. % hydraulic cement, 0.0 to 35 wt. % lime, and 5 to 25 wt. % of an active pozzolan, the continuous phase being uniformly reinforced with polyvinyl alcohol fibers and containing uniformly distributed ceramic microspheres, the spheres having an average diameter of about 10 to 500 microns (micrometers), wherein the polyvinyl alcohol fibers consist of monofilaments and/or multi-filament threads of polyvinyl alcohol optionally modified by a functional group selected from at least one member of the group consisting of carboxyl, amide, nitrile, phosphate, and sulfate, and an optional brightener in the polyvinylalcohol fiber, an optional brightener on the polyvinylalcohol fiber, an optional adhesive agent in the polyvinylalcohol fiber, and an optional adhesive agent on the polyvinyl alcohol fiber, wherein the fibers have a diameter of about 10 to 400 microns (micrometers) and a length of about 0.1 to 1 inches (2.5 to 25.4 mm), and a fiber elastic modulus of 20-50 GPa, and wherein the resulting lightweight building panel has a thickness of 0.25-1.0 in. (6.3-25.4 mm). 2. The panel of claim 1, wherein the continuous phase is uniformly reinforced with the polyvinyl alcohol fibers, the lightweight filler is uniformly distributed. 3. The panel of claim 1, wherein the panel has a Flexural Strength of at least 1000 psi (6.9 MPa) to 1180 psi. 4. The panel of claim 1, wherein the panel has a Flexural Toughness of at least 2.25 Joules depicting total area under the load versus deflection curve for a 4 (102 mm) inches wide, 12 inches (305 mm) long, 0.5 inches (12.7 mm) thick specimen loaded over a span of 10 (254 mm) inches in 4-point bending according to the ASTM C947 test procedure. 5. The panel of claim 1, wherein the panel has a Lateral Fastener Resistance of at least 300 pounds for a 0.5 inch (12.7 mm) thick panel. 6. The panel of claim 1, wherein the polyvinyl alcohol fibers consist of monofilaments and/or multi-filament threads of polyvinyl alcohol and/or polyvinyl alcohol optionally modified by a functional group selected from at least one member of the group consisting of carboxyl, amide, nitrile, phosphate, and sulfate. 7. The panel of claim 1, wherein the lightweight filler comprises hollow ceramic spheres which comprise about 50 to 75 wt. % silica, about 15 to 40 wt. % alumina, and up to 35 wt. % of other materials. 8. The panel of claim 1, wherein the lightweight filler comprises polymer microspheres comprising at least one member of the group consisting of polyacrylonitrile, polymethacrylonitrile, polyvinyl chloride and polyvinylidene chloride, and optionally coated with at least one powder selected from the group consisting of calcium carbonate, titanium oxide, mica, silica and talc. 9. The panel of claim 1, wherein the polyvinyl alcohol fibers have a diameter of about 10 to 100 microns (micrometers) and a length of about 0.2 to 0.5 inches (5.1 to 12.7 mm), and a fiber elastic modulus of 30-50 GPa. 10. The panel of claim 1, wherein the edges are shaped to permit adjacent panels to provide tongue-and-groove. 11. The panel of claim 1, wherein the polyvinyl alcohol fibers constitute approximately 0.5% to 3% by volume of the aqueous mixture on a wet basis. 12. The panel of claim 1, wherein the polyvinyl alcohol fibers constitute approximately 1-3% by volume of the aqueous mixture on a wet basis. 13. The panel of claim 1, wherein the polyvinyl alcohol fibers constitute approximately 1-2% by volume of the aqueous mixture on a wet basis. 14. The panel of claim 1, wherein the polyvinyl alcohol fibers consist of monofilaments and/or multi-filament threads of polyvinyl alcohol modified by a functional group selected from at least one member of the group consisting of carboxyl, amide, nitrile, phosphate, and sulfate. 15. The panel of claim 1, wherein the lightweight filler comprises uniformly distributed polymer spheres having an average diameter of about 10 to 350 μm. 16. The panel of claim 1, wherein the PVA fibers are monofilaments having a length of about 0.25 to 1 inches (6 to 25.4 mm). 17. The panel of claim 1, wherein the hydraulic cement consists essentially of portland cement. 18. The panel of claim 1, wherein the aqueous mixture has a ratio of water-to-reactive powders from greater than 0.3/1 to 0.7/1. 19. The panel of claim 1, wherein the panel has a Flexural Toughness of at least 4.3 Joules depicting total area under the load versus deflection curve for a 4 inches (102 mm) wide, 12 inches (305 mm) long, 0.5 inches (12.7 mm) thick specimen loaded over a span of 10 (254 mm) inches in 4-point bending according to the ASTM C947 test procedure, wherein the polyvinyl alcohol fibers have a diameter of about 10 to 50 microns (micrometers) and a length of about 0.1 to 1 inches (2.5 to 25.4 mm), and a fiber elastic modulus of about 40-50 GPa and wherein the polyvinyl alcohol fibers constitute approximately 1-2% by volume of the aqueous mixture on a wet basis. 20. The panel of claim 1, wherein the polyvinyl alcohol fibers constitute 0.75-5% by weight of the cementitious composition. 21. The panel of claim 19, wherein the panel has a lateral fastener resistance of 335 to 533 pounds and the polyvinyl alcohol fibers have a diameter of about 40 to 50 microns (micrometers) and a length of about 0.25 to 0.75 inches. 22. A structure comprising the panel of claim 1, framing and nails or screws, wherein the panel is attached to the framing by the nails or screws. 23. The panel of claim 1, consisting of a single layer of the continuous phase reinforced with the polyvinyl alcohol fibers and containing the lightweight filler. 24. The building panel of claim 1 consisting of: said continuous phase resulting from the curing of said aqueous mixture of cementitious composition, the cementitious composition consisting of, on a dry basis, 35-70 wt. % reactive powder, 20-50 weight % lightweight filler, 0 weight % glass fibers, and 0.5-5.0 weight % polyvinyl alcohol in the form of polyvinyl alcohol fibers, the continuous phase being reinforced with the polyvinyl alcohol fibers and containing the lightweight filler having a particle specific gravity of from 0.02 to 1.00 and a mean particle diameter size from 50 to 250 microns and/or fall within a particle diameter size range of 10 to 500 microns, wherein the polyvinyl alcohol fibers consist of monofilaments and/or multi-filament threads of polyvinyl alcohol optionally modified by a functional group selected from at least one member of the group consisting of carboxyl, amide, nitrile, phosphate, and sulfate, and an optional brightener in the polyvinylalcohol fiber, an optional brightener on the polyvinylalcohol fiber, an optional adhesive agent in the polyvinylalcohol fiber, and an optional adhesive agent on the polyvinyl alcohol fiber, wherein the fibers have a diameter of about 10 to 400 microns (micrometers) and a length of about 0.1 to 1 inches (2.5 to 25.4 mm), and a fiber elastic modulus of 20-50 GPa, and wherein the resulting lightweight building panel has a thickness of 0.25 -1.0 in. (6.3-25.4 mm). 25. The panel of claim 24, wherein the panel has a Flexural Toughness of at least 4.3 Joules depicting total area under the load versus deflection curve for a 4 inches (102 mm) wide, 12 inches (305 mm) long, 0.5 inches (12.7 mm) thick specimen loaded over a span of 10 (254 mm) inches in 4-point bending according to the ASTM C947 test procedure, and a fiber elastic modulus of about 40-50 GPa and wherein the polyvinyl alcohol, wherein the panel has a lateral fastener resistance of 335 to 533 pounds and the polyvinyl alcohol fibers have a diameter of about 40 to 50 microns (micrometers) and a length of about 0.25 to 0.75 inches polyvinyl alcohol fibers, wherein the fibers constitute approximately 1-2% by volume of the aqueous mixture on a wet basis. 26. The panel of claim 25, wherein the polyvinyl alcohol fibers consist of monofilaments and/or multi-filament threads of polyvinyl alcohol and/or polyvinyl alcohol optionally modified by a functional group selected from at least one member of the group consisting of carboxyl, amide, nitrile, phosphate, and sulfate. 27. The building panel of claim 1 consisting of: said continuous phase resulting from the curing of said aqueous mixture of cementitious composition, the cementitious composition consisting of, on a dry basis, 35-70 wt. % reactive powder, 20-50 weight % lightweight filler, 0 weight % glass fibers, and 0.5-5.0 weight % polyvinyl alcohol in the form of polyvinyl alcohol fibers, the continuous phase being reinforced with the polyvinyl alcohol fibers and containing the lightweight filler having a particle specific gravity of from 0.02 to 1.00 and a mean particle diameter size from 50 to 250 microns and/or fall within a particle diameter size range of 10 to 500 microns, wherein the polyvinyl alcohol fibers consist of monofilaments and/or multi-filament threads of polyvinyl alcohol optionally modified by a functional group selected from at least one member of the group consisting of carboxyl, amide, nitrile, phosphate, and sulfate, wherein the fibers have a diameter of about 10 to 400 microns (micrometers) and a length of about 0.1 to 1 inches (2.5 to 25.4 mm), and a fiber elastic modulus of 20-50 GPa, and wherein the resulting lightweight building panel has a thickness of 0.25-1.0 in. (6.3-25.4 mm). 28. The building panel of claim 1, wherein the panel has a density of 60-75 pcf. 29. A reinforced, lightweight, dimensionally stable building panel having a density of 60-85 pcf (961-1360 kg/m3) and a flexural strength of about 750 psi to about 1180 psi a continuous phase resulting from the curing of an aqueous mixture of a cementitious composition, the cementitious composition consisting essentially of, on a dry basis: 35-70 wt. % reactive powder, 20-50 weight % lightweight filler, 0 weight % glass fibers, and 0.5-5.0 weight % polyvinyl alcohol fibers, the continuous phase being reinforced with the polyvinyl alcohol fibers and containing the lightweight filler having a particle specific gravity of from 0.02 to 1.00 and a mean particle size from 50 to 250 microns and/or fall within a particle diameter size range of 10 to 400 microns, wherein the reactive powder comprises, on a dry basis, portland hydraulic cement and active pozzolan, wherein the polyvinyl alcohol fibers consist of monofilaments and/or multi-filament threads of polyvinyl alcohol optionally modified by a functional group selected from at least one member of the group consisting of carboxyl, amide, nitrile, phosphate, and sulfate, and an optional brightener in the polyvinylalcohol fiber, an optional brightener on the polyvinylalcohol fiber, an optional adhesive agent in the polyvinylalcohol fiber, and an optional adhesive agent on the polyvinyl alcohol fiber, wherein the fibers have a diameter of about 10 to 400 microns (micrometers) and a length of about 0.1 to 1 inches (2.5 to 25.4 mm), and a fiber elastic modulus of 20 -50 GPa, and wherein the lightweight building panel has a thickness of 0.25-1.0 in (6.3-25.4 mm). 30. The panel of claim 29, wherein the continuous phase is uniformly reinforced with the polyvinyl alcohol fibers, the lightweight filler is uniformly distributed. 31. The panel of claim 29, wherein the polyvinyl alcohol fibers consist of monofilaments and/or multi-filament threads of polyvinyl alcohol and/or polyvinyl alcohol optionally modified by a functional group selected from at least one member of the group consisting of carboxyl, amide, nitrile, phosphate, and sulfate. 32. The building panel of claim 29 consisting of: said continuous phase resulting from the curing of said aqueous mixture of cementitious composition, the cementitious composition consisting of, on a dry basis, 35-70 wt. % reactive powder, 20-50 weight % lightweight filler, 0 weight % glass fibers, and 0.5-5.0 weight % polyvinyl alcohol in the form of polyvinyl alcohol fibers, the continuous phase being reinforced with the polyvinyl alcohol fibers and containing the lightweight filler having a particle specific gravity of from 0.02 to 1.00 and a mean particle diameter size from 50 to 250 microns and/or fall within a particle diameter size range of 10 to 500 microns, wherein the polyvinyl alcohol fibers consist of monofilaments and/or multi-filament threads of polyvinyl alcohol optionally modified by a functional group selected from at least one member of the group consisting of carboxyl, amide, nitrile, phosphate, and sulfate, wherein the fibers have a diameter of about 10 to 400 microns (micrometers) and a length of about 0.1 to 1 inches (2.5 to 25.4 mm), and a fiber elastic modulus of 20-50 GPa, and wherein the resulting lightweight building panel has a thickness of 0.25-1.0 in. (6.3-25.4 mm). 33. The building panel of claim 29, wherein the panel has a density of 60-75 pcf.