Packaging prefinished fiber cement products

• US 20040086676A1
• Filed: 07/16/2003
• Published: 05/06/2004
• Est. Priority Date: 07/16/2002
• Status: Active Grant

• Current Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Original Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Inventors: Peng, Weiling
• Granted Patent: US 8,297,018 B2
• Time in Patent Office: Days
• US Class Current: 428/40.1
• CPC Class Codes: B28B 11/04 for coating or applying engobing layersglazing, engobing C04B
• CPC Class Codes: B32B 13/12 of synthetic resin
• CPC Class Codes: B32B 2307/5825 Tear resistant
• CPC Class Codes: B32B 2307/748 Releasability
• CPC Class Codes: B32B 2319/00 Synthetic rubber natural rubber B32B2317/22
• CPC Class Codes: B32B 2323/04 Polyethylene
• CPC Class Codes: B32B 2323/10 Polypropylene
• CPC Class Codes: B32B 2327/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B32B 2333/04 Polymers of esters
• CPC Class Codes: B32B 2363/00 Epoxy resins
• CPC Class Codes: B32B 2367/00 Polyesters, e.g. PET, i.e. polyethylene terephthalate
• CPC Class Codes: B32B 2375/00 Polyureas; Polyurethanes
• CPC Class Codes: B32B 2377/00 Polyamides
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 25/08 of synthetic resin
• CPC Class Codes: B32B 2553/00 Packaging equipment or accessories not otherwise provided for
• CPC Class Codes: B32B 27/28 comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/308 comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/38 : comprising epoxy resins
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 37/12 : characterised by using adhesives
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• 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 2/06 : reinforced
• 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 428/14 : Layer or component removable to expose adhesive
• CPC Class Codes: Y10T 428/1471 : Protective layer
• CPC Class Codes: Y10T 428/1476 : Release layer

Abstract

Protected prefinished fiber cement products are manufactured by applying a protective layer on the finished surface of a fiber cement product. The protective layer protects the finish layer of the prefinished fiber cement product during handling, storage, and transport. Removing the protective layer leaves no adhesive residue on the finish layer, does not damage the finish layer, and does not substantially tear the protective layer. Protected prefinished fiber cement products are typically stacked on pallets for storage and transport. Optionally, spacers may be placed between the stacked protected prefinished fiber cement products.

Claims

1. A protected prefinished fiber cement product comprising:

a fiber cement product, a finish layer applied to the fiber cement product, and a protective layer adhered to the finish layer, wherein

the protective layer protects the finish layer from damage in storage, transport, and handling,

removing the protective layer leaves no residue on the finish layer and does not damage the finish layer, and

the protective layer resists tearing on removal.

2. The protected prefinished fiber cement product of claim 1, wherein the protective layer is adhered to the finish layer with an adhesive.

3. The protected prefinished fiber cement product of claim 2, wherein the adhesive comprises an adhesive material selected from the group consisting of polyacrylate, ethylene acrylic acid, polyvinyl ether, rubber, polyisoprene, polychloroprene, butyl rubber, neoprene rubber, ethylene propylene diene rubber, polyisobutylene, butadiene-acrylonitrile polymer, thermoplastic elastomers, styrene-butadiene rubber, poly-alpha-olefins, amorphous polyolefins, silicones, ethylene-containing copolymers, polyurethanes, polyamides, epoxys, polyvinylpyrrolidone and polyvinylpyrrolidone copolymers, polyesters, mixtures thereof, and copolymers thereof.

4. The protected prefinished fiber cement product of claim 3, wherein the adhesive comprises ethylene acrylic acid.

5. The protected prefinished fiber cement product of claim 2, wherein the adhesive is applied between the finish layer and the protective layer.

6. The protected prefinished fiber cement product of claim 1, wherein the protective layer comprises a polymer film.

7. The protected prefinished fiber cement product of claim 6, wherein the polymer film comprises a polymer resin selected from the group consisting of polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polyester, polyamide, silicone, blends thereof, and copolymers thereof.

8. The protected prefinished fiber cement product of claim 7, wherein the polymer resin is polyethylene.

9. The protected prefinished fiber cement product of claim 1, further comprising an applied spacer.

10. The protected prefinished fiber cement product of claim 9, wherein the spacer is a solid polymer.

11. The protected prefinished fiber cement product of claim 10, wherein the spacer is rubber.

12. The protected prefinished fiber cement product of claim 9, wherein the spacer is from about 0.005 inch to about 0.1 inch thick.

13. The protected prefinished fiber cement product of claim 9, wherein the spacer is from about 0.01 inch to about 2 inch wide.

14. The protected prefinished fiber cement product of claim 1, further comprising a folded spacer comprising a fold in the protective layer.

15. The protected prefinished fiber cement product of claim 1, wherein the protective layer is from about 0.0001 inch to about 0.08 inch thick.

16. The protected prefinished fiber cement product of claim 15, wherein the protective layer is from about 0.0003 inch to about 0.03 inch thick.

17. The protected prefinished fiber cement product of claim 16, wherein the protective layer is from about 0.001 inch to about 0.01 inch thick.

18. An assembly of protected prefinished fiber cement products comprising a plurality of protected prefinished fiber cement articles arranged in a stack, wherein a protected prefinished fiber cement product comprises:

a fiber cement product, a finish layer applied to the fiber cement product, and a protective layer adhered to the finish layer, wherein

the protective layer protects the finish layer from damage in storage, transport, and handling,

removing the protective layer leaves no residue on the finish layer and does not damage the finish layer, and

the protective layer resists tearing on removal.

19. The assembly of claim 18, wherein the protected prefinished fiber cement products are stacked on a pallet.

20. The assembly of claim 18, wherein the protected prefinished fiber cement products are stacked face-to-back.

21. The assembly of claim 18, wherein the protected prefinished fiber cement products are stacked face-to-face and/or back-to-back.

22. The assembly of claim 18, wherein the protected prefinished fiber cement products are banded together.

23. A method of constructing a building comprising:

obtaining a protected prefinished fiber cement product, wherein the protected prefinished fiber cement product comprises

a fiber cement product, a finish layer applied to the fiber cement product, and a protective layer adhered to the finish layer, wherein

the protective layer protects the finish layer from damage in storage, transport, and handling,

removing the protective layer leaves no residue on the finish layer and does not damage the finish layer, and

the protective layer resists tearing on removal;

removing the protective layer; and

fastening the fiber cement product to a building frame.

24. The method of claim 23, wherein the protective layer is removed before the fiber cement product is fastened to the building frame.

25. The method of claim 23, wherein the protective layer is removed after the fiber cement product is fastened to the building frame.

26. A method of manufacturing a protected prefinished fiber cement product, wherein the protected prefinished fiber cement product comprises a fiber cement product and a finish layer applied to the fiber cement product, the method comprising:

adhering a protective layer to the finish layer, wherein

the protective layer protects the finish layer from damage in storage, transport, and handling,

removing the protective layer leaves no residue on the finish layer and does not damage the finish layer, and

the protective layer resists tearing on removal.

27. The method of claim 26, wherein the protective layer is adhered to the finish layer with an adhesive.

28. The method of claim 27, wherein the adhesive comprises an adhesive material selected from the group consisting of polyacrylate, ethylene acrylic acid, polyvinyl ether, rubber, polyisoprene, polychloroprene, butyl rubber, neoprene rubber, ethylene propylene diene rubber, polyisobutylene, butadiene-acrylonitrile polymer, thermoplastic elastomers, styrene-butadiene rubber, poly-alpha-olefins, amorphous polyolefins, silicones, ethylene-containing copolymers, polyurethanes, polyamides, epoxys, polyvinylpyrrolidone and polyvinylpyrrolidone copolymers, polyesters, mixtures thereof, and copolymers thereof.

29. The method of claim 28, wherein the adhesive comprises ethylene acrylic acid.

30. The method of claim 27, wherein the adhesive is applied between the finish layer and the protective layer.

31. The method of claim 26, wherein the protective layer comprises a polymer film.

32. The method of claim 31, wherein the polymer film comprises a polymer resin selected from the group consisting of polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polyester, polyamide, silicone, blends thereof, and copolymers thereof.

33. The method of claim 32, wherein the polymer resin is polyethylene.

34. The method of claim 26, further comprising an applied spacer.

35. The method of claim 34, wherein the spacer is a solid polymer.

36. The method of claim 35, wherein the spacer is rubber.

37. The method of claim 34, wherein the spacer is from about 0.005 inch to about 0.1 inch thick.

38. The method of claim 34, wherein the spacer is from about 0.01 inch to about 2 inch wide.

39. The method of claim 26, further comprising a folded spacer comprising a fold in the protective layer.

40. The method of claim 26, wherein the protective layer is from about 0.0001 inch to about 0.08 inch thick.

41. The method of claim 40, wherein the protective layer is from about 0.0003 inch to about 0.03 inch thick.

42. The method of claim 41, wherein the protective layer is from about 0.001 inch to about 0.01 inch thick.

43. A protective layer with a spacer bonded thereto used for manufacturing a protected prefinished fiber cement product, wherein the protected prefinished fiber cement product comprises:

a fiber cement product, a finish layer applied to the fiber cement product, and a protective layer adhered to the finish layer, wherein

the protective layer protects the finish layer from damage in storage, transport, and handling,

removing the protective layer leaves no residue on the finish layer and does not damage the finish layer, and

the protective layer resists tearing on removal;

the protective layer with a spacer bonded thereto comprising a protective layer and a spacer bonded to a face of the protective layer.

44. The protective layer with a spacer bonded thereto of claim 43 packaged in a roll.

45. The protective layer with a spacer bonded thereto of claim 43, wherein the spacer is a solid polymer.

46. The protective layer with a spacer bonded thereto of claim 45, wherein the spacer is rubber.

47. The protective layer with a spacer bonded thereto of claim 43, wherein the spacer is from about 0.005 inch to about 0.1 inch thick.

48. The protective layer with a spacer bonded thereto of claim 43, wherein the spacer is from about 0.01 inch to about 2 inch wide.

49. The protective layer with a spacer bonded thereto of claim 43, further comprising an adhesive applied to the face of the protective layer opposite to which the spacer is bonded.

50. The protective layer with a spacer bonded thereto of claim 49, wherein the adhesive comprises an adhesive material selected from the group consisting of polyacrylate, ethylene acrylic acid, polyvinyl ether, rubber, polyisoprene, polychloroprene, butyl rubber, neoprene rubber, ethylene propylene diene rubber, polyisobutylene, butadiene-acrylonitrile polymer, thermoplastic elastomers, styrene-butadiene rubber, poly-alpha-olefins, amorphous polyolefins, silicones, ethylene-containing copolymers, polyurethanes, polyamides, epoxys, polyvinylpyrrolidone and polyvinylpyrrolidone copolymers, polyesters, mixtures thereof, and copolymers thereof.

51. The protective layer with a spacer bonded thereto of claim 50, wherein the adhesive comprises ethylene acrylic acid.

52. The protective layer with a spacer bonded thereto of claim 43, wherein the protective layer comprises a polymer film.

53. The protective layer with a spacer bonded thereto of claim 52, wherein the polymer film comprises a polymer resin selected from the group consisting of polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polyester, polyamide, silicone, blends thereof, and copolymers thereof.

54. The protective layer with a spacer bonded thereto of claim 53;

wherein the polymer resin is polyethylene.

55. The protective layer with a spacer bonded thereto of claim 43;

wherein the protective layer is from about 0.0001 inch to about 0.08 inch thick.

56. A method of manufacturing a protective layer with a spacer bonded thereto used for manufacturing a protected prefinished fiber cement product, wherein the protected prefinished fiber cement product comprises:

a fiber cement product, a finish layer applied to the fiber cement product, and a protective layer adhered to the finish layer, wherein

the protective layer protects the finish layer from damage in storage, transport, and handling,

removing the protective layer leaves no residue on the finish layer and does not damage the finish layer, and

the protective layer resists tearing on removal;

the method comprising bonding a spacer to a face of a protective layer.

57. The method of claim 56, further comprising packaging the protective layer with spacers in a roll.

58. The method of claim 56, wherein the spacer is a solid polymer.

59. The method of claim 58, wherein the spacer is rubber.

60. The method of claim 56, wherein the spacer is from about 0.005 inch to about 0.1 inch thick.

61. The method of claim 56, wherein the spacer is from about 0.01 inch to about 2 inch wide.

62. The method of claim 56, wherein the spacer is bonded to the protective layer thermally.

63. The method of claim 56, wherein the spacer is bonded to the protective layer using an adhesive.

64. The method of claim 56, wherein the protective layer further comprises an adhesive applied to the face of the protective layer opposite to which the spacer is bonded.

65. The method of claim 64, wherein the adhesive comprises an adhesive material selected from the group consisting of polyacrylate, ethylene acrylic acid, polyvinyl ether, rubber, polyisoprene, polychloroprene, butyl rubber, neoprene rubber, ethylene propylene diene rubber, polyisobutylene, butadiene-acrylonitrile polymer, thermoplastic elastomers, styrene-butadiene rubber, poly-alpha-olefins, amorphous polyolefins, silicones, ethylene-containing copolymers, polyurethanes, polyamides, epoxys, polyvinylpyrrolidone and polyvinylpyrrolidone copolymers, polyesters, mixtures thereof, and copolymers thereof.

66. The method of claim 65, wherein the adhesive comprises ethylene acrylic acid.

67. The method of claim 56, wherein the protective layer comprises a polymer film.

68. The method of claim 67, wherein the polymer film comprises a polymer resin selected from the group consisting of polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polyester, polyamide, silicone, blends thereof, and copolymers thereof.

69. The method of claim 68, wherein the polymer resin is polyethylene.

70. The method of claim 56, wherein the protective layer is from about 0.0001 inch to about 0.08 inch thick.