Composite building material

• US 20030089061A1
• Filed: 12/16/2002
• Published: 05/15/2003
• Est. Priority Date: 10/10/2000
• Status: Abandoned Application

• Current Assignee: James Hardie International Finance B.V. (James Hardie Industries Plc)
• Original Assignee: James Hardie International Finance B.V. (James Hardie Industries Plc)
• Inventors: Merkley, Donald J., DeFord, Harvey Dale, Gleeson, James A.
• Application Number:
  US10/320,861
• Publication Number:
  US 20030089061A1
• Time in Patent Office: Days
• US Class Current: 52/309.9
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/062 Microsilica, e.g. colloïdal silica preparing microsilica slurries or suspensions C04B18/148
• CPC Class Codes: C04B 14/10 Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 14/30 Oxides other than silica ferrites C04B14/363
• CPC Class Codes: C04B 14/304 Magnesia
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 14/46 Rock wool ; Ceramic or silicate fibres C04B14/40, C04B14/42 take precedence
• CPC Class Codes: C04B 14/48 Metal
• CPC Class Codes: C04B 16/06 fibrous
• CPC Class Codes: C04B 16/08 porous, e.g. expanded polystyrene beads or microballoons
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/101 Burned rice husks or other burned vegetable material
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 18/24 Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper , cork
• CPC Class Codes: C04B 2111/00379 the oriented elements being fibres
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/28 Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: E04C 2/04 of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibresE04C2/26 takes precedence; material or manufacture B28, C04
• CPC Class Codes: E04C 2/043 : of plaster E04C2/049 takes precedence
• CPC Class Codes: E04C 2/049 : completely or partially of insulating material, e.g. cellular concrete or foamed plaster
• CPC Class Codes: E04C 2/3405 : spaced apart by profiled spacer sheets
• CPC Class Codes: E04C 2/365 : by honeycomb structures
• CPC Class Codes: E04C 2002/345 : with triangular corrugations
• CPC Class Codes: E04C 2002/3466 : with sinusoidal corrugations
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

This invention generally pertains to a composite building material comprising a lightweight core with a thin fiber cement facing on one side of the core and a second facing material on the other side. The fiber cement facing that is used on at least one of the faces of the building material is {fraction (3/16)}″ or less, more preferably ⅛″ or less. The green fiber cement facing is preferably formed by a slurry-dewatering process to form a sheet that is in a plastic, uncured, state prior to manufacture of the composite. The composite building material is assembled in an uncured state and then cured.

Claims

1. A building material, comprising:

at least a first component and a second component provided adjacent said first component, wherein said first component is provided as pre-formed, uncured fiber cement, wherein the fiber cement is reinforced with individualized fibers, and wherein the uncured fiber cement is cured after providing the first component adjacent to the second component.

2. The building material of claim 1, wherein the second component is made of a curable material.

3. The building material of claim 2, wherein the first component and the second component are simultaneously cured.

4. The building material of claim 2, wherein the first component and the second component are sequentially cured.

5. The building material of claim 1, wherein the first component is partially dried before providing the first component adjacent the second component.

6. The building material of claim 1, wherein the second component has a density less than that of the fiber cement.

7. The building material of claim 1, wherein the second component is fiber-reinforced.

8. The building material of claim 1, wherein one of the components at least partially surrounds the other component.

9. The building material of claim 8, wherein the first component at least partially surrounds the second component.

10. The building material of claim 1, further comprising a third component provided adjacent said first component such that the first component is located between the second component and the third component.

11. The building material of claim 1, wherein the individualized fibers have a substantially planar orientation.

12. The building material of claim 1, wherein the individualized fibers are substantially oriented in the direction of loading.

13. The building material of claim 1, wherein the fibers are oriented parallel to the fiber cement a surface of the first component.

14. The building material of claim 1, wherein the fiber cement of the first component includes cellulose fibers.

15. The building material of claim 1, wherein the fiber cement of the first component includes natural inorganic fibers.

16. The building material of claim 1, wherein the fiber cement of the first component includes synthetic fibers.

17. The building material of claim 1, wherein the fiber cement of the first component includes engineered fibers.

18. The building material of claim 1, wherein the second component is a lightweight material.

19. The building material of claim 1, wherein the second component is a fire resistive material.

20. The building material of claim 1, wherein the fiber cement of the first component is pressed.

21. The building material of claim 1, wherein the fiber cement of the first component is unpressed.

22. The building material of claim 1, wherein the fiber cement of the first component is moldable.

23. The building material of claim 1, wherein the fiber cement of the first component is embossed.

24. The building material of claim 1, further comprising a sub layer between the first component and the second component to improve bonding therebetween.

25. The building material of claim 1, wherein the second component is a lightweight core having a first side and a second side, and the first component is a pre-formed fiber cement facing on at least the first side of the core.

26. The building material of claim 25, further comprising a second facing on the second side of the core.

27. The building material of claim 25, wherein the fiber cement facing wraps around both the first side and the second side of the core.

28. The building material of claim 25, wherein the facing has a thickness of less than about {fraction (3/16)}″

.

29. The building material of claim 26, wherein the second facing is made from a material selected from the group consisting of fiber cement, a fibrous mat, paper, and a polymeric coating

30. The building material of claim 25, wherein the core is cementitious.

31. The building material of claim 25, wherein the core is solid.

32. The building material of claim 25, wherein the core is open.

33. The building material of claim 25, wherein the core is homogeneous.

34. The building material of claim 25, wherein the core is non-homogeneous.

35. The building material of claim 32, wherein the core has a honeycomb configuration.

36. The building material of claim 32, wherein the core includes a plurality of vertical symmetrically opposed corrugated core layers.

37. The building material of claim 32, wherein the core includes a horizontal, single corrugated layer.

38. The building material of claim 25, wherein the building material is a single plank.

39. The building material of claim 25, wherein the building material is a trim board.

40. A method of manufacturing a building material, comprising:

pre-forming a fiber cement component of predetermined size and shape such that the fiber cement component is in a plastic state and is uncured;

forming a second component made from a curable material adjacent the fiber cement component; and

curing at least the fiber cement component while the fiber cement component is adjacent to the second component to form the building material.

41. The method of claim 40, wherein the second component is made of a curable material.

42. The method of claim 41, wherein the first component and the second component are simultaneously cured.

43. The method of claim 41, wherein the first component and the second component are sequentially cured.

44. The method of claim 40, further comprising partially drying the fiber cement component after forming the second component and before curing at least the fiber cement component.

45. The method of claim 40, further comprising providing the fiber cement component on one side of the second component.

46. The method of claim 45, further comprising providing a third component adjacent a second side of the second component.

47. The method of claim 46, wherein the third component is made of fiber cement.

48. The method of claim 40, wherein the fiber cement component has a thickness of less than about {fraction (3/16)}″

.

49. The method of claim 40, wherein the pre-formed fiber cement component comprises fibers that are substantially aligned along the same plane.

50. The method of claim 40, wherein the fiber cement component includes individualized fibers.

51. The method of claim 40, further comprising providing the fiber cement component at least partially around the second component.

52. The method of claim 40, wherein the second component is a made of a lightweight cementitious material.

53. The method of claim 40, wherein the second component is a made of a fire resistive material.

54. The method of claim 40, further comprising molding the pre-formed fiber cement component into a desired shape while the component is in its uncured, plastic state.