Composite fiber cement article with radiation curable component

• US 20050208285A1
• Filed: 01/12/2005
• Published: 09/22/2005
• Est. Priority Date: 01/12/2004
• Status: Active Grant

• Current Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Original Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Inventors: Lyons, David, Sukkar, Theresa, Merkley, Donald James
• Granted Patent: US 7,754,320 B2
• Time in Patent Office: Days
• US Class Current: 428/292.100
• CPC Class Codes: B32B 13/02 with fibres or particles being present as additives in the layer
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/303 Alumina
• 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 20/0048 Fibrous materials
• CPC Class Codes: C04B 20/1029 Macromolecular compounds
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/22 Carbonation resistance
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 40/0003 making use of electric or wave energy or particle radiation
• CPC Class Codes: C04B 40/0064 Processes of the Magnini or Hatscheck type
• CPC Class Codes: C04B 41/0045 Irradiation; Radiation, e.g. with UV or IR C04B41/0036 takes precedence
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4578 Coating or impregnating of green ceramics or unset concrete
• CPC Class Codes: C04B 41/4826 Polyesters
• CPC Class Codes: C04B 41/483 Polyacrylates
• CPC Class Codes: C04B 41/4884 Polyurethanes; Polyisocyanates
• CPC Class Codes: C04B 41/63 Macromolecular compounds
• CPC Class Codes: E04C 2/044 of concrete E04C2/049 takes precedence
• CPC Class Codes: E04C 5/073 Discrete reinforcing elements, e.g. fibres
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/249924 : Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 428/249953 : Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249988 : Of about the same composition as, and adjacent to, the void-containing component
• CPC Class Codes: Y10T 428/31511 : Of epoxy ether

Abstract

A composite building article is configured with one or more subsurface interfacial zones provided to improve the durability of the article. Each subsurface interfacial zone is made of a matrix of fiber cement and radiation curable material. The radiation curable material forms an interlocking network with the fiber cement to provide a interfacial zone against ingress of environmental agents that can degrade the article. The number, configuration and distribution of the subsurface interfacial zones can vary dependent on the desired characteristics of the final product. The subsurface interfacial zones also improves the adhesion between exterior coatings and the substrate as the interfacial zones can be integrally formed with the substrate as well as exterior coating layer.

Claims

1. A composite building article having a first zone which comprises predominantly fiber cement, a second zone which comprises predominantly a radiation curable material, and a subsurface interfacial zone interposed therebetween, the subsurface interfacial zone comprising an interlocking matrix formed of the radiation curable material and the fiber cement, wherein said interfacial zone is configured to increase durability of the building article.

2. The composite building article of claim 1, wherein the subsurface interfacial zone is integrally formed with the first and second zones.

3. The composite building article of claim 2, wherein the first zone comprises a fiber cement substrate having a porosity of between about 20%-40% by volume.

4. The composite building article of claim 1, wherein the radiation curable material in the subsurface interfacial zone contains substantially no catalyst and is curable primarily by radiation.

5. The composite building article of claim 1, wherein the thickness of the subsurface interfacial zone is controlled by modifying a characteristic selected from the group consisting of the porosity of the first zone, viscosity of the radiation curable component, and combinations thereof.

6. The composite building article of claim 1, wherein the subsurface interfacial zone has a thickness of about 1 μ

m-1,000 μ

m.

7. The composite building article of claim 1, wherein the radiation curable material is selected from the group consisting of epoxies, urethanes, polyesters, acrylates, methacrylates, polyester, polyester epoxies, thiolene acrylics, urethane acrylics, styrene, functionalized styrenes, and mixtures thereof.

8. The composite building article of claim 1, wherein the composite building article is selected from the group consisting of cladding panels, sheets, boards, planks, trims, shakes, and pipes.

13. The building article of claim 1, wherein the radiation curable material is a carbonation reducing sealer.

9. A building article, wherein at least a portion of the matrix of the building article comprises a network formed of fiber cement and a radiation curable material, wherein said network is configured to increase durability of the building article.

10. The building article of claim 9, wherein the radiation curable material is interspersed throughout the matrix of the building article.

11. The building article of claim 9, further comprising reinforcement fibers, wherein at least a portion of the fibers are treated with the radiation curable material.

12. The building article of claim 9, further comprising an exterior coating formed of predominantly the radiation curable material, wherein said exterior coating is integrally formed with the network so as to increase the adhesion between the exterior coating and the matrix of the building article.

14. A method of forming a building product, comprising:

applying a radiation curable material to a fiber cement substrate, wherein said radiation curable material extends into the substrate in a controlled manner and forms a region comprising a mixture of the radiation curable material and fiber cement; and

applying radiation to cure said radiation curable material in the substrate so as to form a three dimensional network of radiation cured material and fiber cement.

15. The method of claim 14, wherein electron beam radiation is applied to cure the radiation curable material.

16. The method of claim 14, wherein the radiation curable material directly contacts the fiber cement substrate.

17. The method of claim 14, wherein the radiation curable material is cured in a multistage process.

18. The method of claim 14, wherein the radiation curable material is applied to the fiber cement substrate using a method selected from the group consisting of roll coating, spraying, curtain coating, and soaking.

19. A method of forming a building product, comprising:

combining a radiation curable material with ingredients for forming a fiber cement composite material;

forming a green sheet, wherein the radiation curable material is distributed throughout at least a portion of the green sheet; and

curing said green sheet to form a building product containing a network of fiber cement and radiation curable material.

20. The method of claim 20, further comprising bonding said green sheet to an uncured fiber cement substrate prior to curing the green sheet.

21. The method of claim 20, further comprising applying a coating of radiation curable material to the building product.