Patent ID: 7445738

Claim:
A process for making fiber-embedded cementitious panels, comprising: using the formula: S f , l P = 4 ⁢ V f * t s , l π ⁢ ⁢ d f ⁡ ( 1 - V f ) for determining a projected fiber surface area fraction of fibers in the resulting panel, said process including: providing a desired slurry fiber volume factor V f ; providing a slurry layer thickness t s,l in the range of 0.05-0.20 inches; adjusting at least one of the fiber diameter d f and the slurry layer thickness T s,l so that the fiber surface area fraction S P f,l , is less than 0.65; providing a supply of loose, individual fibers represented by the fiber volume factor V f determined from the above-calculated fiber surface area fraction S P f,l ,; providing a moving web; depositing a layer of slurry upon said web; depositing said supply of individual loose fibers upon said slurry; and embedding said loose, individual fibers in said slurry so that said fibers are distributed throughout said slurry.