JPS6025265B2 - composite architectural panel - Google Patents

Description

[Detailed description of the invention]

The present invention relates to composite panels for roof structures, architectural assembly, and to methods of manufacturing composite panels. More particularly, the present invention provides a panel comprising a main body of closed cell, generally smooth skin foam material having a protective cementitious overlay material adhered thereto along at least one surface thereof. The present invention relates to panels particularly suitable for use in roofing and curtain wall structures. In this panel, styrene-butadiene-1,
Particularly favorable results are obtained when the tri-copolymer modified Bortland cement is a shrinkage compensating Bortland cement and when such cement contains sufficient reinforcement to provide suppression against expansion. The present invention further provides for one or more regions along the surface of the foam located abutting the protective layer to have depressions therein, preferably in which regions such depressions are hollowed out. Finally, a method of manufacturing a panel is contemplated that includes a portion of the protective coating being contained within such a hole. US Pat. No. 11,256 discloses and claims roof structures of the general type utilized herein. Such prior known structures are essentially roof support means having a roof deck, the roof deck having an upper surface and a lower surface, the upper surface of the roof deck generally having its lower surface adjacent to the roof deck. supporting a water-impermeable membrane having a closed cell foam insulating layer adjacent to the top surface of the water-impermeable membrane, such foam insulating layer being separated from adjacent elements; It consists of a large number of closed-cell foam insulating elements defining an area, and a protective layer of inorganic material, such as mortar, placed on the surface of the insulating elements. However, such prior known roofing structures have suffered from ineffective adhesion of the protective layer to the surface of the insulating element, with the result that such layer does not adhere during normal handling and/or exposure to the environment. causes peeling. Such delamination is primarily due to the development of stresses at the foam-mortar interface due to the normal shrinkage of the preceding known protective layer, resulting in closed-cell, generally flat-surfaced foam insulation. It is believed that this is due to poor bonding of the protective layer to the object. Other factors believed to be responsible for such delamination are temperature cycling during curing of the protective layer due to differences in expansion coefficients between the foam and mortar. US Patent No. 34
By utilizing a roof structure of the type described in the US Pat. No. 11,256, significantly improved resistance to peeling of the protective layer from the foam layer is achieved. According to this, a water or vapor barrier layer is placed on the roof deck, a water-impermeable, closed-cell, generally flat-sided foam insulation is placed on top of the water barrier layer, and a cementitious protective layer is placed on top of the water barrier layer. was placed on the foam insulation, and the cementitious protective layer was modified with a styrene-butadiene-1,3 copolymer. The present invention essentially consists of Bortland cement, a mineral admixture and a styrene to putadiene weight ratio of 30:70.
Styrene-butadiene-1 with 70:30
, 5 to 25 based on the weight of the cement of the 3 copolymer.
%, an amount of water 25 to 65% based on the weight of said cement, and 'a} non-ionic surfactant 2 to 10%, 'b} anionic surfactant 0.75 based on the weight of said copolymer. or 7.5%, of which at least about 15%
% is an alkyl sodium sulfate whose alkyl groups contain from 9 to 17 carbon atoms; a' and {
b} does not exceed about 11% by weight of said non-polymer, and

[The weight ratio of a' to 'b- is about 0.7:1 to 10:
1. A composite architectural panel comprising a main body of closed-cell, generally smooth-skinned foam material having a protective cementitious overlay material bonded along at least one side thereof within the scope of 1. The present invention also provides: 1) providing one or more regions with recesses in the foam surface to be adhered to the cementitious overlay material; 2) applying the cementitious material to the foam surface; 3} vibrating the cementitious material to position a portion of the cementitious material in the recess;
} A method for producing a composite building material, including the steps of curing the cementitious material. The present invention also provides a styrene-butadiene-1,3 copolymer having a styrene to butadiene weight ratio of {1-essentially about 30:70 to 70:30, and based on the weight of said copolymer. 'a} No non-ionic surfactant approx.
about 10%, {b-about 0.75 to 7.5% of anionic surfactant, at least about 15% of which is an alkyl sodium sulfate in which the alkyl group contains 9 to 17 carbon atoms; The sum of 'a) and 'b} is about 1 of the copolymer.
It does not exceed 1% by weight, and the weight ratio of [a' to 'b] is approximately 0.
．． applying to said foam material surface a substantially continuous coating of a thermoplastic styrene-butadiene copolymer latex ranging from 7:1 to 10:1;
21. Applying a cementitious material to the coated surface prior to substantial dewatering of said coating, and then promoting the foam material to form a building panel, comprising the subsequent step of curing said cementitious material. There is a way to do it. The present invention also essentially comprises a roof support means having a roof deck, a roof deck having an upper surface and a lower surface, an upper surface of the roof deck supporting a water or moisture vapor impermeable membrane, the upper surface and generally adjacent the roof deck. an impermeable membrane having a lower surface and a plurality of architectural panels disposed adjacent to a water-impermeable upper surface, the foam material in said plurality of panel elements having no cracks between adjacent elements; (6ssme) in which the surface of the foam insulation layer adjacent to the cementitious protective layer comprises a number of independent indentations, the indentations comprising a portion of the cementitious protective layer; be. The present invention also provides a styrene-butadiene-1,3 copolymer having a styrene to putadiene weight ratio of between about 30:70 and 70:30, and based on the weight of said copolymer [a' About 2 to about 10% non-ionic surfactant
, {b} anionic surfactant about 0.75 to 7.5%
at least about 15% of which is an alkyl sodium sulfate in which the alkyl group contains 9 to 17 carbon atoms, and the sum of wind and b does not exceed about 11% by weight of the polymer. , and a substantially continuous coating of a styrene-butadiene copolymer latex having a weight ratio of (a' to 'b) in the range of about 0.7:1 to 10:1; Prior to application of the cementitious protective layer, the roof structure is coated with the foam insulation layer.The basic roof structure design anticipated by the present invention is described in U.S. Pat.
This is illustrated in Figures 1 and 2 of the '411,256 specification. A wide variety of materials can be used in the manufacture of such roofs. For example, the roof deck or roof support means can be manufactured from steel, wood, laminated wood, cardboard, cement, plasterboard, planks, and the like. The roof deck may be supported in any convenient manner, such as by securing it to rafters with nails, screws or bolts. The roof deck can be from panels, inserted into suitable recesses within the frame, and manufactured by similar methods well known in the art. Water-impermeable membranes include a wide range of coatings that include the conventional asphalt and asphalt compositions used in roofing, as well as laminates of asphalt materials and textile products such as roofing felts using organic or inorganic fibers. The water-impermeable materials may include or consist of any type of water-impermeable material. Advantageously, such felt and gravel materials are formed in alternating layers to provide a water-impermeable membrane of suitable thickness and mechanical strength to withstand movement of roof decks and associated supporting structures. It can be applied in the form of In some cases, the water or vapor impermeable membrane is made of polyethylene, in the presence or absence of a vapor impermeable material such as aluminum foil, adhered to the roof deck by a suitable adhesive.
It can be formed from a synthetic resin film or sheet such as polyvinyl chloride, polyurethane, butyl rubber, polyisobutylene, and the like. One or more layers of such materials may be used depending on the properties desired in the finished structure. The foam insulation layer used in the practice of this invention is a substantially water-impermeable, closed-cell, generally flat-sided material. Particularly convenient and advantageous are styrene polymer foams, styrene-acrylonitrile copolymer foams and styrene-methyl methacrylate copolymer foams, polyvinyl chloride foams, polyurethane foams, polyethylene foams, phenolic resin foams. Cellular plastic foams in closed cell form containing bodies and other water impermeable materials available in the form of cellular foams well known in the art. Examples of other such materials that can be used are ceramic foam and foam glass.
To obtain the best bonding with the latex modified cementitious protective layer described herein, the foam insulation layer includes:
Advantageously, indentations are provided along one or more surfaces, such indentations being of a wide variety of shapes, sizes and frequencies. In more detail, the surface of closed-cell foam can be punched, drilled, embossed, jagged, scored, and scored to create such indentations. Or you can cut it out.
Additionally, various forms of heated protrusions can be used to melt portions of such foam insulation to form the depressions. A particularly useful means for placing depressions in closed cell foam insulation is to pass such foam along a transfer roll having longitudinal projections thereon. This method is particularly useful for placing depressions in styrenic polymer foams due to the inherent resiliency of such foam materials. In this way, such foam is first compressed under a protrusion with a substantially square contact area and then pressed forward. As a result of the combination of compression and resiliency, the foam "tears away from the edges of the initial hole, thereby creating a hole with a larger diameter at the bottom than at the top. In this way, the shape of the hole is It resembles a trapezoid shape with short parallel sides of open holes.A particularly useful cementitious protective layer for use in this invention consists essentially of shrinkage compensating Voltland cement, a mineral admixture, and a styrene to butadiene weight ratio of 30:70. a styrene-butadiene-1,3 copolymer having a ratio of from 5 to 70:30, based on the weight of said cement, 5% to 25%, water based on the weight of said cement, 25% to 65%, and said copolymer; Based on the weight of [a} 2 to 10% nonionic surfactant,'
b' 0.75 to 7.5% of anionic surfactant, of which at least 15% has no alkyl groups, and 17
an alkyl sodium sulfate containing carbon atoms, and {c} without 0.1 and 5% polyorganosiloxane suds suppressor based on the weight of the activated polyorganosiloxane;
The sum of {a} and 'b] does not exceed 11% by weight of the copolymer, and the weight ratio of 'a} to [b} is 0.7:1, and 10
:1, and mixtures of reinforcements that provide restraint against expansion. The shrinkage compensating cement used is as follows. Type K: This is a Bortland cement compound, anhydrous calcium sulfoaluminate (4Ca○・3N203・S0
3), calcium sulfate (CaS04), and lime (C
It is a mixture of a○). The anhydrous calcium sulfoformate is a separately baked clinker that is ground or mixed with the Bortland cement clinker. Alternatively, it can be formed simultaneously with the Volland clinker compound. M
Type: Either a mixture of Bortland cement, calcium aluminate cement and calcium sulfate, or a co-milled product made from Bortland cement clinker, calcium aluminate clinker and calcium sulfate. Type S: Bortland cement containing large quantities of tricalcium aluminate and modified with an excess of calcium sulfate over the normal amount found in other Bortland cements. The styrene-butadiene-1,3 copolymer latex used can be produced by known methods. For example, mixing styrene and butadiene monomers in water containing one or more emulsifiers in proportions corresponding to the composition of the desired copolymer to initiate co-Z polymerization as known in the art. It can be heated under heating in the presence of a peroxide catalyst. However, the concentration of styrene-butadiene-1,3 copolymer solids in the cement composition is limited to Z to obtain the preferred composite properties required by the present invention. In this regard, concentrations of less than 5%, based on the weight of the cement used, do not improve mechanical properties such as bending, abrasion and adhesion. Furthermore, based on the weight of cement, 2
A total latex solids concentration in excess of 5% significantly reduces the mechanical properties of the composition. The use of such copolymer latexes in conventional Bortland cement mortars is known, for example as disclosed in US Pat. No. 3,043,79. If the improved shrinkage compensating cement composition is not properly constrained, it will literally expand on its own and its potency will be severely inhibited or completely lost. Generally, some conventional reinforcing material, such as skewed crosspieces, long rods, or wire mesh, suitably provided in the appropriate amount will provide sufficient restraint to maintain the strength and integrity of the composition. Fiber reinforcing materials such as steel fibers or alkali resistant glass fibers also provide sufficient suppression. The fibrous form can be added to the composition during the mixing stage and will therefore be easily dispersed and become an integral part of the composition. These fibers will be randomly distributed to provide ternary suppression. It has been discovered that the combination of alkali resistant glass fibers and the latex modifications described herein creates unexpected beneficial effects. It has also been discovered that suitably suppressed improved shrinkage compensating cement compositions possess significantly increased freeze-scald resistance, flexural strength and water absorption. The amount of water used in the manufacture of shrinkage compensating cement compositions is also important with respect to providing a composition with maximum work capacity. In this connection, an amount of water of at least 25%, preferably 35% to 65%, based on the weight of the expandable cement is required. Some or all of the non-ionic and anionic surfactants used in the cement compositions of this invention may be present during the copolymerization of styrene and butadiene. However, it is usually preferred to follow the practice used in the production of styrene-butadiene emulsions for use in the production of latex paints. In this way, some but not all of the necessary anionic surfactants are introduced to help effectuate the desired dispersion and emulsification in carrying out the copolymerization of butadiene and styrene, and subsequently A non-ionic surfactant is added to stabilize the dispersion of the resulting polymer. A polyorganosiloxane foam suppressor and additional amounts of non-ionic and anionic surfactants as necessary to complete the cement composition are subsequently introduced. Non-
Examples of ionic surfactants are fatty acid esters such as glycerol monostearate, diethylene glycol laurate, propylene glycol monostearate, sorbitol monolaurate, and pentaerythritol monostearate; 6 moles of ethylene oxide and oleic acid. Acid derivative products of ethylene oxide such as reaction products with 1 mole of acid; condensation products of ethylene oxide and alcohols such as stearyl alcohol; and oxidized products such as di-t-butylzenoxynonaoxyethylene-ethanol. It is a condensation product of ethylene and phenols, naphthols, and alkylphenols. Condensation products of ethylene oxide and alkylphenols are preferred. Examples of anionic surfactants include higher aliphatic alcohols (i.e. at least 9 carbon atoms and usually 17 Sulfate salts of alcohols with not more than carbon atoms; sulfonated animal and vegetable oils such as sulfonated fish oil and castor oil; sulfonated alicyclic hydrocarbons, etc. As mentioned above, at least 15% of the anionic surfactant component of the cement additive of the present invention should be a higher alkyl sodium sulfate, such as lawalyl sodium sulfate, and preferably the anionic surfactant component is It consists of a mixture of sodium alkyl sulfates such as alkylaryl sulfonate surfactants. An example of a polyorganosiloxane is represented by the formula, where R and R' represent an organic group or a double ring group such as alkyl, aryl, aralkyl and alkaryl, and n is 1 or more. It is a condensation product obtained from the polymerization of organosilane diols. Also useful are polymerization products of organosilane diols in the presence of organosilane monools, and condensation products obtained from mixtures of organosilane triols, diols and monools. Preferably, the organic substituents on the siloxanes are lower alkyl (ie, methyl, ethyl, propyl), cyclohexyl, or phenyls. Most preferably it is methyl, and therefore suitable polyorganosiloxanes are those that are condensation products of methylsilicol, most preferably dimethylsilanediol. Polyorganosiloxanes are commonly referred to as "silicon liquids"("smconnuids") in the trade.
), "silicon emulsion"("siliconem■si"
ons") and "silicon compound"("silico
It is commercially available in several forms designated as ``Ncompo Kafune''), the latter being a siloxane modified by the addition of a small percentage of finely divided silica or other inert divided solids. Styrene-butadiene-1,3 as described above can be applied to the foam surface prior to applying the cementitious overlay material.
It has further been found that applying a substantially continuous coating of latex is advantageous for the purpose of obtaining maximum adhesion of the cementitious overlay material to the foam surface. In this connection, it is preferred that the latex coating is not substantially dehydrated before applying the cementitious material. The mixture used for the cementitious protective layer may be any customary manufactured mixture or naturally occurring mineral mixture, such as sand and mixtures of sand with gravel, crushed stone, or equivalent materials. I can do it. The cement composition can be made into an expandable cement by simply adding additives while mixing to obtain a cement mixture of suitable flow and consistency. The styrene-butadiene copolymer, nonionic and anionic surfactants, and polyorganosiloxane foam suppressants are premixed and the resulting mixture is then mixed into cement, mortar, or concrete mixtures. - Although it is common practice to produce cement constituents as unitary products by introducing them into admixture mixtures, it is of course not necessary to mix all types of additives in this way. That will be understood. For example, a styrene-butadiene copolymer emulsion in the required amount containing sufficient anionic and non-ionic surfactants to avoid coagulation of the latex, a polyorganosiloxane foam suppressor and the necessary Separate addition of additional non-ionic and anionic surfactants when appropriate results in homogeneous cement, mortar, or concrete mixtures. In the manufacture of the roof structure of the present invention, a suitable roofing felt is applied to the pebble material, for example by applying a layer of pebble material thereto, and the roofing felt and pebble are removed until a suitable membrane is formed. A water-resistant membrane is typically applied to the roof deck by providing repeated applications of acoustical materials. Advantageously, the foam insulating layer is made into a water-impermeable membrane by the use of the same or a different aqueous composition used in the production of the water-resistant membrane while the aqueous material is in thermoplastic conditions. Glue. Compression of a plank or sheet of thermally insulating material against the acoustic layer provides adequate adhesion. However, it is necessary that the bituminous material does not have a temperature high enough to destroy most or a large proportion of such cellular material. For example, when foamed polystyrene sheets are utilized as the insulating layer, it is generally preferred that the transparent material not have a high temperature above about 100:00 to prevent fracture or melting of such polystyrene foam material. It is essential to the practice of the invention that the insulating layer is in closed cell form. It is only necessary that the particular density or physical strength of such insulating material be sufficient to meet the mechanical requirements of the particular installation. Generally, expanded polystyrene sheets having a density of about 2/1 are suitable to provide a protective layer of sufficient thickness to resist mechanical damage. Thus, in areas where there is little or no roof walking, a protective layer with a thickness of about 0.31 mm provides adequate protection. However, in areas with frequent or heavy walking, it is now preferred to use a layer of cementitious material of about 0.63 to about 0.9 mm or more. It is not a requirement that the protective layer be resistant to the transmission of green matter, nor is it a requirement that the insulating layer have a surface that prevents moisture from contacting the water-resistant membrane. 2 In another embodiment of the present invention, adhesion of a foam insulation layer to a latex modified cementitious layer comprises a styrene-butadiene layer as described herein (but in the absence of a polyorganosiloxane foam suppressor) to the foam insulation. By applying two substantially continuous coatings of latex,
Subsequent substantial dehydration of such a latex coating can be followed by application of a protective layer thereto. With the present invention, the roof structure does not appear to suffer damage from water freezing in the spaces between adjacent foam insulation elements. The present foam insulation elements appear to be sufficiently resilient to resist bursting due to expansion of freezing water in the crevices.
Additionally, temperatures adjacent to water-resistant membranes in heated building installations typically do not reach freezing temperatures. In buildings with roofs adapted according to the invention, little or no tendency for moisture to condense on the inner surface of the roof deck is observed. For further explanation, the thickness is about 3.17 melons, and the medium is about 60 mm.
．． Closed cell with dimensions of 9.9 mm and length of approximately 121.9 mm,
Multiple pieces of polystyrene foam with a generally flat surface were advanced along a roll having independent protrusions thereon. The protrusions are approximately 1.27 arcs apart in both directions, and have a cross-sectional area of approximately 0.31 x 0.31 and a height of approximately 0.97
It was the skin. These protrusions created a number of depressions in the foam, which were trapezoidal in shape with short parallel sides of holes closing on the surface of the foam. Thereafter, such a dimpled foam surface is made of essentially about 66% of styrene.
about 4% by weight of a solid copolymer consisting of 1,3% by weight of butadiene and 1,3% by weight of milk, based on the weight of said copolymer;
about 4.65% of the nonionic surfactant di-tert-butylphenoxynonaethylene-ethanol and about 0.78% of a mixture of anionic surfactants including a large amount of sodium lauryl sulfate and a corresponding small amount of dodecylbenzene sulfonate.
A styrene-butadiene latex of the present invention (Latex A) consisting of an aqueous emulsion of (Latex A) was coated with a substantially continuous coating. One-third of the cementitious protective layer is then applied to the coated side of the foam prior to meaningful dewatering of the latex coating.
A 2 inch coating was cast. The cementitious protection material used was a K-type shrinkage compensating cement with sufficient water to form a water-to-cement ratio of 0.29 to 0.635, and a sand-to-cement ratio of approximately 2.75-1 to 3.
11 of said styrene-butadiene latex, an amount of said styrene-butadiene latex to give about 15% latex solids, based on the weight of the cement, an amount of said styrene-butadiene latex to give about 0.4% by weight of active silicon, based on the weight of the latex solids. A polymethylsiloxane foam suppressor was prepared by mixing approximately 1.81 kg of alkali-resistant glass fiber of 1.27 length per 42.62 kg of cement to polish the suppressor. K type compensating cement is Bortland cement compound, anhydrous calcium sulfoaluminate (Ca○) 4 (A
I203)3 (S03), calcium sulfate (CaS04
), and lime (Ca0). The cementitious protective layer was then vibrated to create trapped air and position a portion of such cementitious layer into the depressions present in the foam. The panels so formed were then cured at ambient temperature. The cured panels were characterized by excellent resistance to delamination. More specifically, from 9.4℃ to 29. 30 to ㅅ○
According to the temperature cycle of group M, or from 10qC to 60℃
No delamination occurred following 500 temperature cycles.
Additionally, the cured panels meet the ASTM test standards. C-666
There were features exhibiting freeze-to-blind values greater than 300 cycles, ie, such panels did not deteriorate significantly following such temperature cycles. To further illustrate the superior adhesion obtained through the use of the latex A formulated in accordance with the present invention, one of the latex materials in each series of tests was a closed-cell, generally flat-sided polystyrene foam. was cast as a substantially continuous coating on a piece of. The latex materials used were: Latex A...(as described above) Latex B...Depending on the latex, but further containing a polymethylsiloxane suds suppressant in an amount to provide about 0.4% by weight of active silicon, based on the weight of latex solids. Latex C... (for comparison) About 25% by weight of Latex A above, ■about 75% by weight of vinylidene chloride, about 2% by weight of vinyl chloride, about 3% by weight of ethyl acrylate, and about 2% by weight of methyl methacrylate.
A mixture with about 75% by weight latex consisting of an aqueous emulsion consisting of: Latex D (for comparison) Based on Latex C, but with additional addition of a small amount of polymethylsiloxane foam suppressor. Each coated foam sample was tested for tensile bond strength by adhering the coated foam sample between opposing pieces of wood via an epoxy adhesive. Tensile bond strength was obtained by pulling the wood pieces apart and moving the point of separation. The following table describes the samples used and the results obtained. The above figures explain that by using Latex A unexpectedly large adhesion forces are achieved. Panels made as described herein are particularly useful in building construction, such as roof panels or sidewall construction panels. For comparison, conventional Boltland cement as described herein but without {a1 latex modification and reinforcement or {b
'Panels manufactured using fiber-reinforced shrinkage compensating cements of the type disclosed in detail herein, without latex modification, both exhibit significant deterioration over a temperature cycle of about 20°C. was there. Roof structures were made using panels formulated in accordance with the present invention by mopping roofing grade asphalt onto a wood roof deck and then applying roofing felt thereto. This procedure was repeated until a water-resistant membrane was formed.
A number of cement-coated foam panels are then bonded (cementitious coating on top) to the top surface of this water-resistant membrane by means of a hot spray having a temperature of about 100 qo. The resulting roof structure is characterized by having a weight of less than about 2.26 k9 per about 92 fall, and when exposed to repeated temperature cycles of about 37.7°C and a total temperature difference of up to 93.3 qo. There was no peeling of the cementitious layer from the foam. Such roof structures are further rated A fire class (C
It is characterized by its ability to support undercarriage and normal loads or impacts without cracking, and is light in color and capable of reflecting sunlight, thus preventing high temperatures from building up in the insulation. Additionally, after a long exposure period, sections of the membrane were removed to evaluate elasticity. Cement Latex The thin film placed on the underside of the modified cement coated expanded polystyrene equipment was in excellent condition and did not exhibit any signs of excessive hardening. For comparison, a similar membrane coated with gravel and having a 2 inch layer of cellular styrene placed below the roof deck showed significant degradation. For further illustration, Styrene, when used as a modifier in cement and as a primer coating on generally closed-cell polymeric foam surfaces with holes and dimples in insulating layers. The following comparative examples are provided to highlight the unique adhesion properties obtained with n-butadiene-1,3. Example 1 A cementitious composition was prepared from the following mixture. Stone earth and sand (mason saM) (ASTMC-144) 300 female type 1 cement (ASTMC-150) 100 female and water
231 g of this cement composition was mixed and poured into a number of cup-shaped molds each having a diameter of 9.95 mm or an equivalent surface area of 77.8 mm. The cup shape with the cement mixture therein was placed inverted onto a closed cell, generally smooth skin polystyrene foam backing, and the cement was placed on top and allowed to cure.
After 2 hours, the cement had hardened enough that the mold could be removed, leaving a disc-shaped piece of cement adhered to the foam backing. The cement was then allowed to harden for an additional 6 days. A load was applied to the composite disc-shaped piece and the load was gradually increased until separation of the cement piece from the foam backing was obtained. The load obtained upon separation of the cement pieces from the foam backing was recorded and immediately converted to k9 per square centimeter. The following results were obtained. Table 1 An average load of 0.178 k9/h was obtained in this series of tests, demonstrating the low bond strength between the cement pieces and their foam backing. Example la A series of tests similar to those in Example 1 were conducted with a cement composition containing the following mixture: Masonry Sand (ASTM C-144) 13.6k9 Peerless Type 1 Cement (ASTM
C-150) A load was applied to each of a number of cement pieces of this composition bonded to foam backings of 4.53X9 and Water 2.31K9 respectively. The following results were obtained. Table la An average load of only 0.149 k9 per square centimeter was obtained in this series of tests, again indicating no benefit of the styrene-butadiene copolymer latex as a cement modifier or primer coating on foam slopes. This demonstrates the low bond strength of the cement pieces when bonded to a STYROFOAM backing with a smooth skin. EXAMPLE 2 Tests conducted with the cement composition of Example la were first applied to a flat-sided, closed-cell plastic foam board with a substantial portion of the styrene-butadiene-1,3 copolymer latex described herein. A continuous undercoat was applied to the base coat (with the exception of polyorganosiloxane foam suppressor).
Other than that, I repeated the same to the aircraft. The cement composition was allowed to cure for 7 days on the prime coated foam board. The following load test results were recorded. □ An average load of 1.068 k9/h was obtained in this series of tests, which represents a substantial improvement in the load capacity obtained by the unique latex primer coating between the foam backing and the cement molding. Example 3 A cement composition containing 15% of the composition described herein (including a polyorganosiloxane foam suppressor)
A series of tests were conducted with the cement composition of Example la, except that it was modified with a weight percent styrene-eptadiene-1,3 copolymer latex. For this cement, the latex composition is calculated as a latex solids content of 48%. This latex modified cement composition contained the following amounts: masonry sand
13.6k9 Peerless Type 1 Cement
Styrene-ptadiene-1,3 copolymer 4.53k9 latex (48% solids) 1.44[9 water
0.36k 9th order load test results were recorded. An average load of 1.26k9/ground was obtained in this series of tests, which represents a further improvement in bond strength obtained with the latex modified cement compared to the series of tests derived in Example 2. prove Example 4 Example 3 is further provided that the foam board is first provided with a substantially continuous coating of styrene-butadiene-1,3 copolymer latex adhesive (no polyorganosiloxane foam suppressor). A series of experiments were conducted with the same latex modified cement mixture. The cement composition was allowed to cure for 7 days at the same time as the primer coating. The following results were recorded. Table IV An average load of 2.024 [9/min] was obtained before separation of the foam board from the cement piece occurred. The results of this load are far superior to the test results of Examples 2 and 3 and also show a high degree of robustness. This stiffness is due to the fact that its load value approaches the tensile strength of the foam backing itself. It is observed that the separation between each concrete piece and the foam backing is not always a clean separation between these two constituents, but rather that the foam rather than the interface between the concrete piece and the backing The result was rupture of the lining. Example 5 A further series of tests were conducted using a 71' weight percent styrene eptagene latex adhesive in the cement mixture of Example 3. The cement mixture thus contained the following amounts: masonry sand
1.36kg Peerless type 1 cement 4. Ball kg styrene-butadiene-1
, 3 copolymer latex (48% solids) 723. Chicks and water
1650g The following results were recorded. Table V An average load of 0.243 k9/base was obtained, which is the result obtained with the 15 wt % latex modified cement composition of Example 3 using about 1'a amount of latex adhesive in the cement composition. indicates that it is substantially less effective than Example 6 The test series of Example 5 was repeated except that the foam board was first provided with a substantially continuous coating of styrene-butadiene-1,3 copolymer latex adhesive, and the cement composition was Allowed to harden for days. The following results were recorded. Table 1: An average load of 103k9 was obtained, which represents a substantial improvement over the unprimed foam board of Example 5. The results also show that the 15% by weight latex modified cement of Example 4 provides substantially better results. Example 7 Molded cement pieces were produced in the manner of Example 1. This cement piece was made from the following mixture: masonry sand
3000 type 1 cement
1000 evenings and Wednesdays
A number of indentations were made in the foam board by a number of 0.317 diameter brass pins placed in a staggered relationship on the board having a surface area of 412.9 mm. 98 pins are installed on the board, and the total pin area is 7
．． It was the 74th time. This arrangement created 21 impressions or indentations in the 77.87 mm surface area of the foam backing covered by the circular cement pieces. The depth of the depression into the foam board was kept at 0.21 arc. The following results were recorded. An average of only 0.126 k9/ground was obtained in this series of tests with perforated recessed foam boards. This test did not provide any improvement over the results obtained in the test of Example 1, although the provision of recesses in the foam board reasonably expected an increase in adhesion of the cement pieces to the foam board. It was also not shown. Example 8 A series of tests similar to those of Example 7 except that the foam board was first given a substantially continuous coating of styrene-butadiene-1,3 copolymer latex adhesive (no foam suppressor). A test was conducted. An equal number of indentations were first applied to the foam board to an average depth of about 0.21 mm. The following results were recorded. 1st plate table 0.639k
An average load of 9/ground was obtained, indicating a substantial improvement in load capacity over the test conducted in Example 7. Surprisingly, this primed perforated foam board did not exhibit any improvement over the primed but unperforated foam board of Example 2. Example 9 Example 5
A latex modified cement mixture was prepared by. The foam board was indented as in Example 7.
However, the average depth of the depressions was only 0.086 cucumbers. The following test results were recorded. An average load of 0.335 k9/c was obtained, which represents a slight improvement over the perforated plate of Example 5. Example 10 First, styrene-butadiene-1 was applied to a foam board.
, 3 copolymer latex adhesive (no suds suppressor) was repeated except to provide a substantially continuous coating of the copolymer latex adhesive (no foam suppressor). The following results were recorded. Table X An average load of 1.146 kg/ground was obtained, which represents a substantial improvement in load capacity over the unprimed foam board of Example 9. Example 11 A series of tests were conducted in which latex modified cement moldings were prepared from the following mixtures: Masonry sand 3000 type 1 cement 1000 Tastyrene-butadiene-1,3 copolymer latex (48% solids) 319 type and water
This mixture contained 15% by weight latex solids in the cement. A closed cell, generally flat surfaced polystyrene foam was indented to a depth of 0.85 inches in substantially the same manner as in Example 7. however,
The foam backing was not given a latex base coat. The following test results were recorded. An average load of 1.722 k9/h was obtained, representing a substantial improvement over the test conducted with the unperforated foam board of Example 3. Example 12 A final series of tests were conducted similar to those of Example 11, except that the foam board was also provided with a substantially continuous coating of styrene-butadiene-1,3 copolymer latex adhesive. . The following results were recorded. An average load of 2.046 k9/base was obtained, which is slightly greater than the 15 wt.% latex modified cement molding and primed coated foam board (but non-perforated foam board) given in Example 4. Show good results. All the tests were carried out in a greenhouse at a temperature of 22.70 and a relative humidity of 50%. In each case, the mold was removed after 2 hours, after which the cement was allowed to sit for an additional 6 days to allow uniform hardening of the cement pieces. Although the tests of Example 12 provide only slight improvements over the tests conducted in Example 4, they do not in any way diminish the desirability of providing dimples in the foam board. This is because they provide substantial lateral support to the cement layer. As will be apparent from the foregoing specification, the invention is capable of embodying various modifications and improvements that may differ in detail from those set forth in the foregoing specification and description.

Claims (1)

Claims: 1. essentially Portland cement, mineral aggregate, and a styrene-butadiene-1,3-copolymer having a styrene to butadiene weight ratio of 30:70 to 70:30 based on the weight of said cement. 5 to 25% water, based on the weight of the cement, and 25 to 65% water, based on the weight of the copolymer, (a) 2 to 10% nonionic surfactant, (b) at least about 15% of the copolymer. 0.75 to 7.5% of an anionic surfactant which is an alkyl sodium sulfate containing an alkyl group having from 9 to 17 carbon atoms; and (c) 0.75% of a polyorganosiloxane suds suppressor based on the weight of the active polyorganosiloxane. 1 to 5% of the copolymer, wherein the sum of (a) and (b) does not exceed about 11% by weight of the copolymer;
) to (b) in the range of 0.7:1 to 10:1 by weight, a closed-cell foam having a generally smooth skin with a protective cementitious overlay material adhered along at least one side thereof. Composite architectural panels made mainly of body materials. 2. The architectural panel of claim 1, wherein the foam material is a styrene polymer foam. 3. The surface of the foam material adjacent to the cementitious material includes one or more regions having depressions, the depressions ultimately forming part of the overlay material. Architectural panels in Section 1. 4. The architectural panel of claim 3, wherein the depressions in the foam are hollow-shaped depressions, and the depressions open in the foam surface are generally ladder-shaped with short parallel sides. 5. The non-ionic surfactant in the cementitious material is di-t-butyl-phenoxynonaoxyethylene-ethanol, and the anionic surfactant is comprised of a mixture of alkylaryl sulfonate and alkyl sodium sulfate. , and the polyorganosiloxane foam suppressor is polymethylsiloxane. 6. The architectural panel of claim 5, wherein the alkylaryl sulfonate is sodium dodecylbenzenesulfonate, and the sodium alkyl sulfate is sodium lauryl sulfate. 7 The copolymer in the cementitious material is about 66% styrene.
% and about 34% butadiene. 8. The architectural panel according to claim 1, wherein the Portland cement is a shrinkage compensating cement. 9. The architectural panel of claim 1, wherein the cementitious material includes sufficient reinforcement to provide expansion restraint. 10. The architectural panel of claim 9, wherein the reinforcement is alkali-resistant glass fiber. 11 A method of manufacturing a composite architectural panel having a generally smooth skin having a protective cementitious overlay material bonded to a closed cell foam material body, the method comprising: (a) having one or more skins on said foam surface; (b) the foam surface comprises essentially Portland cement, mineral aggregate, and a styrene to butadiene weight ratio of 30:70 to 70:30 based on the weight of the cement; 5-25% styrene-butadiene-1,3-copolymer, 25-65% water based on the weight of said cement, and 2-10% based on the weight of said copolymer (a) a nonionic surfactant; , (b) 0.75 to 7.5% of an anionic surfactant, at least about 15% of which is an alkyl sodium sulfate containing alkyl groups having from 9 to 17 carbon atoms, and (c) an activated polyorganosiloxane. A mixture of 0.1 to 5% polyorganosiloxane foam suppressor by weight, comprising (a) and (b)
does not exceed about 11% by weight of the copolymer, and (
applying a protective cementitious material having a weight ratio of a) to (b) in the range of 0.7:1 to 10:1; and (c) vibrating said cementitious material to remove a portion of said cementitious material. A method of manufacturing a composite architectural panel comprising: (d) curing the cementitious material. 12. A portion of the styrene-butadiene-1,3 copolymer in the overlay material is coated with a latex prior to applying a protective cementitious overlay material over the main body of foam material. 11. Method for manufacturing architectural panels.