Reinforced fiber cement article and methods of making and installing the same

• US 20030054123A1
• Filed: 04/03/2002
• Published: 03/20/2003
• Est. Priority Date: 04/03/2001
• Status: Active Grant

• Current Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Original Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Inventors: Black, Andrew J., Peng, Weiling
• Granted Patent: US 7,713,615 B2
• Time in Patent Office: Days
• US Class Current: 428/34.4
• CPC Class Codes: B28B 1/002 assembled from preformed elements
• CPC Class Codes: B32B 13/02 with fibres or particles being present as additives in the layer
• CPC Class Codes: B32B 13/06 of metal
• CPC Class Codes: B32B 13/12 of synthetic resin
• CPC Class Codes: B32B 2307/542 Shear strength
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: C08G 2170/20 Compositions for hot melt adhesives
• CPC Class Codes: C09J 175/04 Polyurethanes
• CPC Class Codes: E04F 13/0864 composed of superposed elements which overlap each other and of which the flat outer surface includes an acute angle with the surface to cover
• CPC Class Codes: E04F 13/0896 with adhesive joining strips E04F13/0894, E04F13/0898 take precedence
• CPC Class Codes: E04F 13/141 with an outer layer of concrete E04F13/147 takes precedence
• CPC Class Codes: E04F 13/148 with an outer layer of asbestos cement or the like
• CPC Class Codes: E04F 13/16 of fibres or chips, e.g. bonded with synthetic resins , or with an outer layer of fibres or chips E04F13/0864 takes precedence
• CPC Class Codes: Y10T 428/131 Glass, ceramic, or sintered, fused, fired, or calcined metal oxide or metal carbide containing [e.g., porcelain, brick, cement, etc.]
• CPC Class Codes: Y10T 428/24124 Fibers
• CPC Class Codes: Y10T 428/24777 Edge feature
• CPC Class Codes: Y10T 428/249932 Fiber embedded in a layer derived from a water-settable material [e.g., cement, gypsum, etc.]

Abstract

In one embodiment, a reinforced fiber cement article comprising a fiber cement piece and a reinforcing fixture bonded to a portion of the fiber cement piece for improving the performance, strength and durability of the fiber cement piece. The reinforcing fiber cement article could be used as or in conjunction with a siding plank assembly, which further comprises an interlocking feature that allows the siding plank to be stacked with other siding planks in a manner such that a uniform and deep shadow line is created. The interlocking feature sets the gauge of the exposed plank face and allows for leveling of the plank during installation. The reinforcing fixture could also serve as a thick butt piece or a plastic spline that produces a deep shadow line. A cementitious adhesive is used to bond the reinforcing fixture to the fiber cement piece.

Claims

1. A reinforced fiber cement article, comprising:

a fiber cement article having a front surface and a back surface; and

a reinforcing fixture bonded along a length of at least one of the front surface and the back surface to improve the strength of the fiber cement article.

2. The reinforced article of claim 1, further comprising a high-shear strength adhesive layer situated between the fiber cement article and the reinforcing fixture.

3. The reinforced article of claim 2, wherein the high-shear strength adhesive layer covers a portion of the front surface of the fiber cement article for bonding the reinforcing fixture to the fiber cement article.

4. The reinforced article of claim 2, wherein the high-shear strength adhesive layer covers a portion of the front surface and the back surface of the fiber cement article for bonding the reinforcing fixture to the front and back surface of the fiber cement article.

5. The reinforced article of claim 1, wherein the reinforcing fixture has a tensile strength greater than the fiber cement article.

6. The reinforced article of claim 1, wherein the reinforcing fixture is more flexible than the fiber cement article.

7. The reinforced article of claim 1, wherein the reinforcing fixture is a metal foil.

8. The reinforced article of claim 1, wherein the reinforcing fixture is a woven metal mesh.

9. The reinforced article of claim 1, wherein the reinforcing fixture is a polymer film.

10. The reinforced article of claim 1, wherein the reinforcing fixture is a polymer fabric mesh.

11. The reinforced article of claim 10, wherein the polymer fabric mesh is non-woven.

12. The reinforced article of claim 1, wherein the reinforcing fixture has a thickness, width, and length.

13. The reinforced article of claim 12, wherein the length of the reinforcing fixture is substantially the same as the length of the fiber cement article.

14. The reinforcing article of claim 12, wherein the reinforcing fixture is an interlocking member.

15. The reinforcing article of claim 14, wherein the interlocking member is a butt piece.

16. The reinforcing article of claim 14, wherein the interlocking member is a plastic spline.

17. The reinforcing article of claim 12, wherein the reinforcing fixture is a nailing skirt for attaching and supporting the fiber cement article to the exterior of a building.

18. The reinforced article of claim 1, wherein the fiber cement article is a flat siding plank.

19. The reinforced article of claim 1, wherein the fiber cement article is a roofing shake.

20. The reinforced article of claim 1, wherein the fiber cement article has a hollow extruded profile.

21. The reinforced article of claim 1, wherein the fiber cement article has a length extending from one end to another end of the article and the reinforcing fixture extends along the entire length of the article.

22. A method for making a fiber cement article with a localized reinforcing fixture, comprising:

determining points of stress on the fiber cement article;

selecting a reinforcing fixture for improving the strength of the fiber cement article at the points of stress; and

bonding the reinforcing fixture to the points of stress on the fiber cement article.

23. The method of claim 22, wherein determining points of stress on the fiber cement article involves analyzing the stresses on the fiber cement article in its installation of intended use.

24. The method of claim 22, wherein selecting a reinforcing fixture comprises determining the shape, dimension, and appropriate material based on a stress analysis of the fiber cement article in its installation or intended use.

25. The method of claim 24, wherein selecting a reinforcing fixture further comprises fabricating the reinforcing fixture.

26. The method of claim 22, wherein bonding the reinforcing fixture to the fiber cement article comprises applying an adhesive to a surface of the article.

27. The method of claim 26, wherein bonding the reinforcing fixture further comprises applying an adhesive to a surface of the fixture.

28. The method of claim 26, wherein the reinforcing fixture is attached to a surface of the fiber cement article after an adhesive is applied to the article surface.

29. The method of claim 28, wherein a pressure is applied to the reinforcing fixture and article after the reinforcing fixture is attached to the surface of the fiber cement article.

30. The method of claim 29, wherein the fiber cement article and reinforcing fixture are held in place in a press for a predetermined amount of time, pressure, and temperature in order to permanently bond them together.

31. The method of claim 30, wherein the fiber cement article with the localized reinforcing fixture is removed from the press.

32. The method of claim 22, wherein the reinforcing fixture selected is an interlocking member.

33. The method of claim 22, wherein the reinforcing fixture selected is a nailing skirt for attaching and supporting the fiber cement article to the exterior of a building.

34. The method of claim 22, wherein the fiber cement article is a flat siding plank.

35. The method of claim 22, wherein the fiber cement article selected from the group consisting of a roofing shake, slate, and tile.