Coated substrate having one or more cross-linked interfacial zones

• US 20070042192A1
• Filed: 08/18/2005
• Published: 02/22/2007
• Est. Priority Date: 08/18/2005
• Status: Active Grant

• Current Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Original Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Inventors: Luo, Caidian, Nguyen, Van
• Granted Patent: US 7,758,954 B2
• Time in Patent Office: Days
• US Class Current: 428/420
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/46 with organic materials
• CPC Class Codes: C04B 41/483 Polyacrylates
• CPC Class Codes: C04B 41/4853 Epoxides
• CPC Class Codes: C04B 41/4876 Polystyrene
• CPC Class Codes: C04B 41/4922 applied to the substrate as monomers, i.e. as organosilanes RnSiX4-n, e.g. alkyltrialkoxysilane, dialkyldialkoxysilane
• CPC Class Codes: C04B 41/502 Water
• 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 41/71 at least one coating being an organic material
• CPC Class Codes: Y10T 428/249955 Void-containing component partially impregnated with adjacent component
• CPC Class Codes: Y10T 428/249956 Void-containing component is inorganic
• CPC Class Codes: Y10T 428/249958 Void-containing component is synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/249967 Inorganic matrix in void-containing component
• CPC Class Codes: Y10T 428/249968 Of hydraulic-setting material
• CPC Class Codes: Y10T 428/249986 Void-containing component contains also a solid fiber or solid particle
• CPC Class Codes: Y10T 428/31511 Of epoxy ether
• CPC Class Codes: Y10T 428/31536 Including interfacial reaction product of adjacent layers
• CPC Class Codes: Y10T 428/31663 : As siloxane, silicone or silane

Abstract

A coated substrate is configured with one or more cross-linked interfacial zones provided to improve the adhesion between the coating and substrate of the article or between adjacent coating layers. The coating composition contains molecules having at least two reactive functional groups capable of reacting with cross-linking molecules in the substrate and/or molecules in adjacent coating layers. The cross-linked interfacial zones improve the adhesion between coatings and the substrate and between adjacent coating layers.

Claims

1. A building article comprising:

a substrate containing hydroxyl functional groups;

a first composition coated over at least a portion of the substrate, wherein a portion of the first composition extends into a subsurface region of the substrate, said first composition comprising a plurality of cross-linking molecules wherein each molecule has at least two reactive functional groups, each functional group being capable of forming chemical bonds with the hydroxyl functional groups in the substrate; and

a first cross-linked interfacial zone comprising an interlocking matrix formed in the subsurface region of the substrate, said interlocking matrix comprising hydroxyl functional groups in the subsurface region bonded to and cross-linked by the cross-linking molecules in the portion of the first composition.

2. The composite building article of claim 1, wherein the cross-linking molecules are selected from the group consisting of vinylalkoxy silane, epoxy-tertiary amine, epoxy, metal complexity compounds, glycidoxypropyltrimethoxysilane, carboxylic acid, hydroxyl-carboxylic acid, or combinations thereof.

3. The composite building article of claim 1, wherein the first composition consists essentially of a vinylalkoxy silane sealer and a water-based acrylic latex topcoat.

4. The composite building article of claim 1, wherein the first composition consists essentially of a water-based epoxy sealer and a water-based acrylic latex topcoat.

5. The composite building article of claim 1, wherein the first composition consists essentially of a dilute citric acid pre-sealer and a styrene-acrylic latex sealer.

6. The composite building article of claim 1, further comprising a second composition coated over at least a portion of the first composition.

7. The composite building article of claim 6, further comprising a second cross-linked interfacial zone formed at the interface between the first and second compositions, wherein molecules in the second composition are cross-linked by and bonded to cross-linking molecules in the first composition.

8. The composite building material of claim 7, wherein the molecules in the second composition are cross-linked by and bonded to secondary functional groups in the first composition.

9. The composite building article of claim 7, wherein the first composition is a basecoat and the second composition is a topcoat.

10. The composite building article of claim 1, wherein the first composition comprises a carboxylic acid pre-sealer.

11. The composite building article of claim 1, wherein the first composition comprises a citric acid pre-sealer.

12. The composite building article of claim 1, wherein said building article is a fiber reinforced cementitious material.

13. The composite building article of claim 1, wherein the substrate is part of a fiber cement cladding panel.

14. The composite building article of claim 1, wherein the substrate is part of a fiber cement siding.

15. The composite building article of claim 1, wherein the substrate is part of a fiber cement column.

16. A composite building article having a first zone which comprises predominantly cement, a second zone which comprises predominantly a base coat material, and a first interfacial zone interposed therebetween, said first interfacial zone comprising an interlocking matrix formed of a portion of the basecoat material and the fiber reinforced cement, wherein the base coat material comprises molecules, each molecule having at least two primary functional groups, wherein the primary functional groups bond with functional groups in the fiber reinforced cement substrate to form cross-linking bonds in the interfacial zone.

17. The composite building article of claim 16, further comprising a second interfacial zone formed by cross-linking at least two secondary functional groups in the base coat material with functional groups in a second coating material, wherein said second coating material is formed on an upper surface of the base coat material.

18. The composite building material of claim 16, wherein said second coating material has a different composition than the base coat material.

19. The composite building article of claim 16, wherein the composite building article is selected from the group consisting of cladding panels, sheets, boards, fascia, trim, fencing, roofing, planks, trims, shakes, and pipes.

20. The composite building article of claim 16, wherein the first interfacial zone is about 0 to 50 microns thick.

21. The composite building article of claim 16, wherein the second interfacial zone is about 0 to 50 microns thick.

22. A method of forming a building article, comprising:

applying a first composition to an exterior surface of a substrate, wherein a portion of said composition extends into a subsurface region of the substrate in a controlled manner; and

reacting the portion of said composition with molecules in the subsurface regions in a manners so as to form a cross-linked interfacial zone.

23. The method of claim 22, wherein applying the first composition comprises applying more than one layer of coating composition.

24. The method of claim 22, wherein said coating composition is selected from the group consisting of vinylalkoxy silane, epoxy-tertiary amine, epoxy, metal complexity compounds, glycidoxypropyltrimethoxysilane, carboxylic acid, hydroxyl-carboxylic acid, or combinations thereof.

25. The method of claim 22, wherein said coating composition comprises a basecoat composition.