Durable high performance fibre cement product and method on manufacture

• US 20060182946A1
• Filed: 03/31/2004
• Published: 08/17/2006
• Est. Priority Date: 03/31/2003
• Status: Abandoned Application

• Current Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Original Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Inventors: Silva, Leonard, Zarb, Joseph Emmanual, O'Chee, Milton Terrence
• Application Number:
  US10/551,873
• Publication Number:
  US 20060182946A1
• Time in Patent Office: Days
• US Class Current: 428/312.400
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 18/082 Cenospheres
• 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 20/0048 Fibrous materials
• CPC Class Codes: C04B 20/1051 Organo-metallic compounds; Organo-silicon compounds, e.g. bentone
• CPC Class Codes: C04B 20/1066 Oxides, Hydroxides
• CPC Class Codes: C04B 2111/00129 Extrudable mixtures
• CPC Class Codes: C04B 2111/22 Carbonation resistance
• CPC Class Codes: C04B 2111/29 Frost-thaw resistance
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 38/00 Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof treating slag with gases or gas generating material C04B5/06 ; expanded graphite C04B35/536
• CPC Class Codes: C04B 38/0054 the pores being microsized or nanosized
• CPC Class Codes: C04B 40/0064 Processes of the Magnini or Hatscheck type
• CPC Class Codes: C04B 40/0071 making use of a rise in pressure
• CPC Class Codes: C04B 40/024 Steam hardening, e.g. in an autoclave
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/483 Polyacrylates
• CPC Class Codes: C04B 41/4853 Epoxides
• CPC Class Codes: C04B 41/4884 Polyurethanes; Polyisocyanates
• 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 41/522 : Multiple coatings, for one of the coatings of which at least one alternative is described
• CPC Class Codes: C04B 41/63 : Macromolecular compounds
• CPC Class Codes: C04B 41/71 : at least one coating being an organic material
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/249968 : Of hydraulic-setting material
• CPC Class Codes: Y10T 428/31511 : Of epoxy ether
• CPC Class Codes: Y10T 428/31551 : Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31935 : Ester, halide or nitrile of addition polymer

Abstract

An engineered fibre reinforced cement product including a first major surface to which a carbonation reducing sealer is applied and a second generally opposing major surface to which a carbonation reducing sealer is applied, so as to reduce propensity for differential carbonation in the product. A method of manufacturing a durable fibre reinforced cement product, said method comprising steps of: (e) mixing a wet fibre reinforced cement formulation; (f) forming from said formulation a green product defining first and second generally opposing major surfaces; (g) curing the green product to form a cured product; and (h) applying a carbonation reducing sealer to said first and second major surfaces, so as to reduce propensity for differential carbonation in the product. An engineered fibre reinforced cement product including a first major surface with a reduced propensity to differential carbonation, wherein the product has a cement to silica ratio of between 0.29 and around 0.51 and a porosity of between 25% and around 45%.

Claims

1. An engineered fibre reinforced cement product including a first major surface to which a carbonation reducing sealer is applied and a second generally opposing major surface to which a carbonation reducing sealer is applied, so as to reduce propensity for differential carbonation in the product.

2. A product according to claim 1, wherein a carbonation reducing sealer is applied to substantially all surfaces of the product.

3. A product according to claim 1, wherein the carbonation reducing sealer applied to at least one of said first and second major surfaces is a radiation curable sealer.

5. A product according to claim 1, wherein the sealer applied to at least one of said first and second major surfaces is thermally, air or chemically curable.

6. A product according to claim 1, wherein the sealer applied to at least one of said first and second major surfaces is composed substantially of a formulation selected from the group comprising:

acrylics;

epoxy acrylates, and urethane acrylate sealers.

7. A product according to claim 1, wherein the sealer applied to at least one of said first and second major surfaces includes an integral adhesion promoting formulation.

10. A product according to claim 1, wherein the sealer applied to at least one of said first and second major surfaces includes an adhesive formulation adapted to enhance bonding of a topcoat.

11. A product according to claim 1, wherein the sealer applied to at least one of said first and second major surfaces is covered by a separate keycoat adapted to enhance bonding of a topcoat.

13. A product according to claim 1, wherein the sealer applied to each of the major surfaces is between 15 microns and around 80 microns in overall thickness.

19. A product according to claim 1, wherein the carbonation reducing sealer is substantially alkali resistant.

20. A product according to claim 1, wherein the carbonation reducing sealer is sufficiently cross-linked to impede migration of carbon dioxide through the sealer to a predetermined extend.

23. A product according to claim 1, wherein the sealer has a cement to silica ratio of between 0.2 and around 1.5 on a dry weight basis.

29. A product according to claim 1, having a porosity of between 30% and around 60%.

31. A product according to claim 1, having a relative density of between 0.5 and around 2.0

35. A product according to claim 1, being a fibre reinforced cement sheet product configured by use as an exterior cladding panel.

37. A product according to claim 35, wherein the first major surface of the sheet product is a mounting surface adapted for inward orientation toward a substrate and the second major surface of the sheet product is an exposed surface adapted for outward orientation.

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38. A method of manufacturing a durable fibre reinforced cement product, said method comprising steps of:

(a) mixing a web fibre reinforced cement formulation;

(b) forming from said formulation a green product defining first and second generally opposing major surfaces;

(c) curing the green product to form a cured product; and

(d) applying a carbonation reducing sealer to said first and second major surfaces, so as to reduce propensity for differential carbonation in the product.

40. A method according to claim 38, wherein the carbonation reducing sealer applied to at least one of said first and second major surfaces is a radiation curable sealer.

43. A method according to claim 38, wherein the sealer applied to at least one of said first and second major surfaces is selected from the group comprising:

acrylics;

epoxy, acrylates, and urethane acrylate sealers.

44. A method according to claim 38, wherein the sealer applied to at least one of said first and second major surfaces includes an integral adhesion promoting composition.

47. A method according to claim 38, wherein the curing step is performed using a process selected from the group comprising:

autoclave, air and steam curing.

48. A method according to claim 38, wherein the product is a sheet product configured for use as an exterior cladding panel.

52. A method according to claim 38, wherein one or more of the chemical composition of the formulation, method of manufacture, and physical structure of the cured product, are selected to reduce propensity for carbonation in the product.

53. A method according to claim 52, including the further step of compressing said green product prior to curing in a controlled manner such that the cured product exhibits a reduced carbonation gradient.

65. A method according to claim 38, wherein the carbonation reducing sealer is applied in multiple coats or stages.

69. A method according to claim 38, wherein the carbonation reducing sealer applied to at least one of the major surfaces is cured in multiple stages.

70. A method according to claim 69, including the further step of applying a keycoat over the sealer following partial curing and prior to full curing, to enhance bonding between the sealer and the keycoat.

71. A method according to claim 69 or claim 70, including the further step of applying a topcoat over the sealer following partial curing and prior to full curing, to enhance bonding between the sealer and the topcoat.

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50. A method according to claim 50, wherein the first major surface of the sheet product is a mounting surface adapted for inward orientation toward a substrate and the second major surface of the sheet product is an exposed surface adapted for outward orientation.

51. A method according to claim 50, wherein the substrate is a supporting frame.

54. A method according to claim 50, wherein the cured product has a porosity of between 30% and around 60%.

56. A method according to claim 50, wherein the cured product has a relative density of between 0.5 and around 2.0.

58. A method according to claim 50, wherein said wet fibre reinforced cement formulation has a cement to silica ratio of between 0.2 and around 1.5 on a dry weight basis.

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72. An engineered fibre reinforced cement product including a first major surface with a reduced propensity to differential carbonation, wherein the product has a cement to silica ratio of between 0.29 and around 0.51 and a porosity of between 25% and around 45%.

73. A product according to claim 72, including a major surface to which a carbonation reducing sealer is applied.

74. A product according to claim 73, wherein a carbonation reducing sealer is applied to substantially all surfaces of the product.

75. A product according to claim 73 or claim 74, wherein the carbonation reducing sealer is a radiation curable sealer.