Building materials with bioresistant properties

• US 20050126430A1
• Filed: 12/16/2004
• Published: 06/16/2005
• Est. Priority Date: 10/17/2000
• Status: Abandoned Application

• Current Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Original Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Inventors: Ormonde, Trina Ann, Lightner, James Edward Jr., Luo, Caidian, Merkley, Donald James
• Application Number:
  US11/014,635
• Publication Number:
  US 20050126430A1
• Time in Patent Office: Days
• US Class Current: 106/15.50
• CPC Class Codes: B27K 3/005 employing compositions comprising microparticles
• CPC Class Codes: B27K 3/22 Compounds of zinc or copper
• CPC Class Codes: B27K 3/343 Heterocyclic compounds
• CPC Class Codes: C04B 14/06 Quartz; Sand
• 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 18/241 Paper, e.g. waste paper; Paper pulp
• CPC Class Codes: C04B 18/26 Wood, e.g. sawdust, wood shavings
• CPC Class Codes: C04B 20/0036 Microsized or nanosized
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 20/1018 with organic materials pigments or dyes C04B20/1096
• CPC Class Codes: C04B 20/1022 Non-macromolecular compounds
• CPC Class Codes: C04B 20/1051 Organo-metallic compounds; Organo-silicon compounds, e.g. bentone
• CPC Class Codes: C04B 20/107 Acids or salts thereof
• CPC Class Codes: C04B 2103/0016 Cu
• CPC Class Codes: C04B 2103/67 Biocides
• CPC Class Codes: C04B 2111/00405 Materials with a gradually increasing or decreasing concentration of ingredients or property from one layer to another
• CPC Class Codes: C04B 2111/00577 applied by spraying mixtures shapable by spraying C04B2111/00155
• CPC Class Codes: C04B 2111/0062 Gypsum-paper board like materials
• CPC Class Codes: C04B 2111/2092 Resistance against biological degradation
• CPC Class Codes: C04B 22/002 Water
• CPC Class Codes: C04B 22/062 : of the alkali or alkaline-earth metals
• CPC Class Codes: C04B 24/128 : Heterocyclic nitrogen compounds
• CPC Class Codes: C04B 24/2611 : Polyalkenes
• CPC Class Codes: C04B 26/04 : obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/04 : Portland cements
• CPC Class Codes: C04B 28/14 : containing calcium sulfate cements gypsum-paper plates E04C
• CPC Class Codes: C04B 40/0039 : Premixtures of ingredients
• CPC Class Codes: C04B 41/009 : characterised by the material treated
• CPC Class Codes: C04B 41/4535 : applied as a solution, emulsion, dispersion or suspension
• CPC Class Codes: C04B 41/48 : Macromolecular compounds
• CPC Class Codes: C04B 41/52 : Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
• CPC Class Codes: C04B 41/61 : Coating or impregnation
• CPC Class Codes: C04B 41/62 : with organic materials
• CPC Class Codes: C09D 5/14 : Paints containing biocides, e.g. fungicides, insecticides or pesticides C09D5/16 takes precedence
• CPC Class Codes: D21H 17/13 : Silicon-containing compounds
• CPC Class Codes: D21H 17/59 : obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon
• CPC Class Codes: D21H 21/16 : Sizing or water-repelling agents
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

A building article incorporating a biocidal agent, such as copper oxine, that inhibits the growth of mold, fungi, algae, mildew, bacteria, lichen, and other undesirable biological growth is provided. The biocidal agent can be a biocide, fungicide, germicide, insecticide, mildewcide, or the like. The biocidal agent can be interspersed throughout the matrix of the article; applied as a surface treatment to the article; or applied as a treatment to the fibers reinforcing the article. The building article can include tile backer boards, decks, soffits, trims, decking, fencing, roofing, cladding, sheathing, and other products. The building article can also include a variety of different composite materials such as cement, gypsum, wood, and wood/polymer composites.

Claims

1. A building article comprising copper oxine as a biocide for inhibiting mold growth, wherein said building article is comprised of a material selected from the group consisting of cement, fiber cement, gypsum, gypsum fiber composite, wood, hardboard, medium density fiberboard, oriented strandboard, and wood/polymer composites.

2. The building article of claim 1, wherein the copper oxine is mixed into and interspersed throughout at least a portion of the material forming the article.

3. The building article of claim 1, wherein the copper oxine is adhered to a first surface of the article.

4. The building article of claim 3, wherein the copper oxine directly contacts the first surface of the article.

5. The building article of claim 4, wherein the copper oxine extends from the first surface into subsurface layers of the building article.

6. The building article of claim 3, further comprising a coating formed on the first surface of the article to cover the copper oxine thereon.

7. The building article of claim 6, wherein said coating is selected from the group consisting of primers, sealants, and paints.

8. The building article of claim 1, wherein the biocide comprises about 0.025% to 2% copper oxine by weight of the material forming the article.

9. The building article of claim 1, wherein the building article is selected from the group consisting of tile backer boards, decks, soffits, trims, decking, fencing, roofing, cladding, and sheathing.

10. The building article of claim 1, wherein the building article comprises a gypsum based core having two opposing surfaces and paper sheets bonded to said opposing surfaces.

13. The building article of claim 1, wherein the building article comprises a board.

14. The building article of claim 1, wherein the building article comprises a plank.

15. The building article of claim 1, wherein the building article comprises a stake.

16. The building article of claim 1, wherein the building article is reinforced with cellulose fibers.

12. The building article of claim 12, wherein copper oxine is applied to fibers reinforcing the paper sheets.

11. The building article of claim 12, wherein copper oxine is adhered to at least one surface of the paper sheets.

17. A method of forming a building article that is resistant to mold growth, comprising:

forming a building article having a first surface, said building article is comprised of a material selected from the group consisting of cement, fiber cement, gypsum, gypsum fiber composite, wood, hardboard, medium density fiberboard, oriented strandboard, and wood/polymer composites; and

applying copper oxine to said first surface, wherein said first surface is selected from the group consisting of exterior surface, unfinished surface, pre-finished surface, and finished surface.

18. The method of claim 17, wherein the copper oxine is applied directly to said first surface.

19. The method of claim 17, wherein the copper oxine is applied to said first surface via a solution comprising about 0.1%-2% copper oxine, about 1%-10% additives and about 50%-99% water.

20. The method of claim 19, wherein said additives are selected from the group consisting of sealants, primers, and paints.

21. The method of claim 17, wherein forming a building article comprises forming a fiber cement board.

22. The method of claim 17, wherein forming a building article comprises forming a gypsum board.

23. The method of claim 17, wherein forming a building article comprises forming a wood composite board.

24. The method of claim 17, wherein forming a building article comprises forming a plank.

25. The method of claim 17, wherein forming a building article comprises forming a stake.

26. A method of forming a building material that is resistant to mold growth, comprising:

combining copper oxine with ingredients for forming a composite material selected from the group consisting of cement, fiber cement, gypsum, gypsum fiber composite, wood, hardboard, medium density fiberboard, oriented strandboard, and wood/polymer composites;

forming a mixture comprising the copper oxine and said ingredients wherein the biocide is dispersed throughout at least a portion of the mixture; and

processing said mixture to form a building material which incorporates the copper oxine therein.

27. The method of claim 26, wherein said ingredients comprise a hydraulic binder, aggregates, and fibers.

28. The method of claim 27, wherein processing said mixture comprises processing the copper oxine and ingredients into a green shaped article, followed by autoclave curing of said green shaped article.

29. The method of claim 26, wherein said building material comprises a panel.

30. The method of claim 26, wherein said building material comprises a plank.

31. The method of claim 26, wherein said building material comprises a stake.

32. A method of forming a fiber reinforced building material that is resistant to mold growth, comprising:

combining copper oxine treated fibers with ingredients for forming a composite material selected from the group consisting of cement, fiber cement, gypsum, gypsum fiber composite, wood, hardboard, medium density fiberboard, oriented strandboard, and wood/polymer composites; and

forming a building material that is reinforced with said copper oxine treated fibers.

33. The method of claim 32, wherein said copper oxine treated fibers comprises copper oxine treated cellulose fibers.

34. A building article comprising fiber cement and a biocide, wherein said biocide directly contacts the fiber cement and substantially inhibits mold growth therein.

35. The building article of claim 34, wherein said biocide is interspersed throughout at least a portion of the fiber cement.

36. The building article of claim 34, wherein said biocide is applied to a first surface of said article and contacts the fiber cement on said first surface.

37. The building article of claim 36, wherein the biocide penetrates the first surface of the article and extends into subsurface layers of the article.

38. The building article of claim 37, wherein the biocide extends into the article from said first surface for a depth of at least 10 microns.

39. The building article of claim 34, wherein said biocide is selected from the group consisting of copper oxine, zinc stearate, calcium borate, zinc borate, barium borate, zinc omadine, zinc omadine/zinc oxide mix, sub 10 micron copper powder, and mixtures thereof.

40. The building article of claim 34, wherein said biocide is substantially stable in an alkali environment.

41. The building article of claim 34, wherein the article is selected from the group consisting of primed fiber cement articles, prefinished fiber cement articles, tile backer boards, decks, soffits, trims, decking, fencing, roofing cladding, and sheathing.

42. The building article of claim 34, wherein the building article is a fiber cement sheet.

43. The building article of claim 34, wherein the building article is a gypsum plank.

44. The building particle of claim 34, wherein the building article is a hardboard.

45. A building material formulation, comprising:

a formulation for forming a composite material selected from the group consisting of cement, fiber cement, gypsum, gypsum fiber composite, wood, hardboard, medium density fiberboard, oriented strandboard, and wood/polymer composites; and

an admixture comprising a biocide.

46. The building material formulation of claim 45, wherein the admixture comprises a biocide selected from the group consisting of copper oxine, zinc stearate, calcium borate, zinc borate, barium borate, zinc omadine, zinc omadine/zinc oxide mix, sub 10 micron copper powder, and mixtures thereof.

47. The building material formulation of claim 45, wherein the admixture comprises a timed-release biocide.

48. The building material formulation of claim 45, wherein the admixture comprises a biocide solution mixed with a predetermined amount of porous glass, ceramic, mineral, or polymeric material so as to permit timed release of the biocide.

49. The building material formulation of claim 45, wherein the admixture comprises about 0.025-2% by weight of the formulation.

50. A method of forming a building article that is resistant to mold growth, comprising:

forming a fiber cement article having a first surface, wherein said first surface is selected from the group consisting of exterior surface, pre-finished surface and finished surface; and

applying a biocide to the first surface, wherein said biocide directly contacts said fiber cement.

51. The method of claim 50, wherein applying said biocide comprises applying a copper oxine solution.

52. The method of claim 50, further comprising applying a sealant to the fiber cement article after applying the biocide to the first surface of the article.

53. The method of claim 50, wherein applying said biocide comprises spraying a solution containing said biocide directly to the first surface.

54. The method of claim 50, wherein applying said biocide comprises applying a biocide having a viscosity of between about 1 and 1,000 centipoises.

55. The method of claim 50, wherein the biocide is applied to the first surface by a method selected from the group consisting of spray coating, dip coating, curtain coating, roller or brush coating, flooding, and vacuum coating.