Cementitious panels, and systems and methods for manufacturing cementitious panels

1. A cementitious panel, comprising:

a cementitious core material;

a plurality of sheets of facing material surrounding the cementitious core material, the plurality of sheets of facing material comprising a first sheet of facing material and a second sheet of facing material; and

a radiation-cured adhesive applied to the first sheet of facing material and/or to the second sheet of facing material so as to adhere the first sheet of facing material to the second sheet of facing material.

2. The cementitious panel of claim 1 , wherein the radiation-cured adhesive comprises an adhesive that is cured with ultraviolet radiation.

3. The cementitious panel of claim 1 , wherein the radiation-cured adhesive comprises an adhesive that is cured with infrared radiation.

4. The cementitious panel of claim 1 , wherein the radiation-cured adhesive comprises an adhesive that is cured with electron-beam radiation.

5. The cementitious panel of claim 1 , wherein the radiation-cured adhesive comprises an epoxide, a urethane, a polyether, a polyester, an epoxy resin, a styrene, an acrylate, a vinyl ether, a lactone, a lactam, a cyclic ether, a cyclic acetyl, a cyclic siloxane, N-Vinylpyrrolidone, and/or N-vinylcarbazole.

6. The cementitious panel of claim 1 , wherein the radiation-cured adhesive is in the form of an intermittent pattern of ribbons, beads, lines, dots, or spots.

7. The cementitious panel of claim 1 , wherein the cementitious core material comprises a hydraulically setting material.

8. The cementitious panel of claim 1 , wherein the cementitious core material comprises gypsum and/or cement.

9. The cementitious panel of claim 1 , wherein at least one of the plurality of sheets of facing material is at least partly embedded in the cementitious core material.

10. The cementitious panel of claim 1 , wherein at least one of the plurality of sheets of facing material comprises one or more layers of woven or non-woven fibers or filaments.

11. The cementitious panel of claim 10 , wherein the fibers or filaments comprise a thermoplastic material, a thermoset material, and/or a glass material.

12. The cementitious panel of claim 1 , wherein at least one of the plurality of sheets of facing material comprises a paper or paperboard material.

13. A method of manufacturing a cementitious panel, the method comprising:

conveying a slurry of cementitious core material and a plurality of sheets of facing material, the plurality of sheets of facing material comprising a first sheet of facing material and a second sheet of facing material;

applying a radiation-curable adhesive to the first sheet of facing material and/or to the second sheet of facing material;

forming a continuous length of cementitious panel material comprising the slurry of cementitious core material surrounded by the plurality of sheets of facing material;

at least partly curing the radiation-curable adhesive with one or more beams of radiation emitting from one or more radiation-emitting devices, so as to adhere the first sheet of facing material to the second sheet of facing material; and

cutting the continuous length of cementitious panel material laterally to a desired length, providing a cementitious panel.

14. The method of claim 1 , wherein the radiation-curable adhesive comprises an epoxide, a urethane, a polyether, a polyester, an epoxy resin, a styrene, an acrylate, a vinyl ether, a lactone, a lactam, a cyclic ether, a cyclic acetyl, a cyclic siloxane, N-Vinylpyrrolidone, and/or N-vinylcarbazole.

15. The method of claim 13 , wherein the radiation-curable adhesive comprises an ionic initiator and/or a free radical initiator.

16. The method of claim 13 , wherein the radiation-curable adhesive has substantially cured prior to cutting the continuous length of cementitious panel material.

17. The cementitious panel of claim 1 , comprising applying the radiation-curable adhesive to the first sheet of facing material and/or to the second sheet of facing material in the form of an intermittent pattern of ribbons, beads, lines, dots, or spots.

18. The method of claim 13 , comprising turning the cementitious panel over at a wet transfer table comprising an articulating lifting and lowering mechanism, wherein the radiation-curable adhesive has substantially cured prior to turning the cementitious panel over.

19. The method of claim 13 , wherein the radiation-curable adhesive comprises an adhesive that is curable with ultraviolet radiation, and wherein the one or more radiation-emitting devices comprise an ultraviolet radiation-emitting device.

20. The method of claim 13 , wherein the radiation-curable adhesive comprises an adhesive that is curable with infrared radiation, and wherein the one or more radiation-emitting devices comprise an infrared radiation-emitting device.

21. The method of claim 13 , wherein the radiation-curable adhesive comprises an adhesive that is curable with electron-beam radiation, and wherein the one or more radiation-emitting devices comprise an electron-beam emitting device.

22. The method of claim 13 , wherein the cementitious core material comprises a hydraulically setting material.

23. The method of claim 13 , wherein the cementitious core material comprises gypsum and/or cement.