Composite product

• US 6,893,751 B2
• Filed: 03/04/2002
• Issued: 05/17/2005
• Est. Priority Date: 03/02/2001
• Status: Expired due to Term

• Current Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Original Assignee: James Hardie Research Pty., Limited (James Hardie Industries Plc)
• Inventors: Cottier, John Sydney, Naji, Basil, Lyons, Robert
• Primary Examiner(s): STEIN, STEPHEN J
• Application Number:
  US10/090,406
• Publication Number:
  US 20020192510A1
• Time in Patent Office: 1,170 Days
• Field of Search: 428/703, 428/446, 428/323, 428/325, 428/336, 106/624, 106/692, 106/712, 106/737, 106/705, 106/DIG.1
• US Class Current: 428/703
• CPC Class Codes: B28B 1/522 for producing multi-layered articles B28B1/526, B28B1/527 take precedence
• CPC Class Codes: B28B 7/46 for humidifying or dehumidifying
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 20/008 Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder colloidal silica C04B14/062 ; silica fume C04B18/146
• CPC Class Codes: C04B 2111/00482 Coating or impregnation materials
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: E04C 2/06 reinforced
• CPC Class Codes: E04F 13/02 of plastic materials hardening after applying, e.g. plaster surface treatment in painting technique B44D; inorganic or bituminous masses C04B; organic plastics C08L ; implements for applying plasticised materials E04F21/02
• CPC Class Codes: E04F 15/12 Flooring or floor layers made of masses in situ, e.g. seamless magnesite floors, terrazzo gypsum floorsinorganic or bituminous masses C04B; organic plastic masses C08L
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 106/01 Fly ash
• CPC Class Codes: Y10T 428/249932 Fiber embedded in a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
• CPC Class Codes: Y10T 428/249968 Of hydraulic-setting material
• CPC Class Codes: Y10T 428/249972 Resin or rubber element
• CPC Class Codes: Y10T 428/249986 Void-containing component contains also a solid fiber or solid particle
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/265 1 mil or less
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31667 Next to addition polymer from unsaturated monomers, or aldehyde or ketone condensation product
• CPC Class Codes: Y10T 442/10 : Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]

Abstract

A composite product comprising a substrate layer and one or more functional layers applied thereto. The slurry is applied to the substrate layer to form a functional layer and the functional layer dewatered through the substrate layer. The functional layers can be repeated to build up a laminated composite product. Functional additives may be included in each layer to provide desired properties to that layer and indeed to the subsequent composite product.

Claims

1. A composite product comprising a substrate layer and one or more functional layers applied thereto, each functional layer including a mixture of hydraulic binder and a dewatering agent wherein the dewatering agent comprises fly ash, and a reinforcing layer at least partially covering said functional layer, said reinforcing layer comprising a fiber reinforced cementitious layer.

2. A composite product according to claim 1, wherein additives and/or fillers are incorporated in the functional layer(s) to provide the desired acoustic properties, thermal or fire performance, density modification, cost or production efficiency, compressive or tensile strength, water permeability, density or aesthetic properties to the composite product.

3. A composite product according to claim 1, wherein the dewatering agent is provided in a sufficient quantity to maintain porosity in the functional layer(s) and the substrate layer during dewatering.

4. A composite product according to claim 1, wherein the dewatering agent is a particulate material.

5. A composite product according to claim 1, wherein the dewatering agent is selected from the group consisting of fly ash, alumina trihydrate, silica flour, cenospheres and mixtures thereof.

6. A composite product according to claim 1, wherein the product is cured by air curing, steam curing or hydrothermally cured in an autoclave.

7. A composite product according to claim 1, wherein the product is a cementitious building board or product or gypsum building board.

8. A composite product according to claim 1, wherein the thickness of the functional layer on the product is between about 0.1 and 10 mm.

9. A composite product according to claim 1, wherein the hydraulic binder used in the functional layer is selected from the group consisting of white, grey or pigmented cements, hydraulic limes and mixtures thereof.

10. A composite product according to claim 1, wherein the binder in the functional layer is between about 10 and 50 wt % based on total dry ingredients.

11. A composite product according to claim 1, wherein the dewatering agent includes a coarse fraction fly ash having a particle size diameter greater than about 100 microns.

12. A composite product according to claim 1, wherein the functional layer includes additives to improve the properties of the substrate layer such that upon dewatering of the functional layer, the substrate layer is thus treated with said additive.

13. A composite product according to claim 1, wherein the quantity of dewatering agent is sufficient to permit de-watering of each functional layer through the substrate layer and any additional functional layer.

14. The composite material according to claim 1, wherein each functional layer includes one or more functional additives to provide one or more physical and/or chemical properties to that layer.

15. A composite product according to claim 1, wherein the substrate layer is a fibre reinforced base material.

16. A composite product according to claim 1, wherein the substrate layer is a reinforced cementitious product.

17. A composite product according to claim 1, wherein the functional layers are added to both sides of the substrate layer.

18. A composite product according to claim 1, wherein the functional layers are added to one side of the substrate layer.

19. A composite product according to claim 1, wherein the reinforcing layer comprises fibre mesh or netting.

21. A composite product according to claim 10, wherein the functional layers have a low fiber content relative to the fibre reinforced cementitious layers.

20. A composite product comprising a substrate layer and one or more functional layers applied thereto, each functional layer including a mixture of hydraulic binder and determining agent wherein the dewatering agent comprises fly ash, the composite products having outer layers provided by fiber reinforced cementitious layers with one or more functional layers positioned therebetween.

22. A composite product comprising a substrate layer and one or more functional layers applied thereto, each functional layer including a mixture of hydraulic binder, dewatering agent wherein the dewatering agent comprises:

i) about 10 to 60% of the formulation based on total dry ingredients of a first fly ash component having a particle diameter between about 1 and 100 microns; and

ii) about 5 to 30% of the formulation based on total dry ingredients of a second fly ash component having a maximum particle size diameter of around 10 microns.

23. The composite material comprising:

a substrate layer; and

a functional layer formed on a first surface of the substrate layer, the functional layer comprising a hydraulic binder and a determining agent, wherein the dewatering agent has a pre-selected configuration and is added in a pre-selected quantity to the hydraulic binder to shorten the dewatering time of the functional layer in a manner such that the drainage time of the functional layer in a 50 ml volume funnel is decreased to less than about 4.5 seconds, wherein the dewatering agent is selected from the group consisting of fly ash, alumina trihydrate, silica flour, cenospheres and mixtures thereof, wherein the dewatering agent comprises (i) about 10 to 60% of the formulation based on total dry ingredients of a first fly ash component having a particle diameter between about 1 and 100 microns; and

(ii) about 5 to 30% of the formulation based on total dry ingredient of a second fly ash component having a maximum particle size diameter of about 10 microns.

24. The composite material of claim 23, wherein the functional layer comprises a slurry composition having a water to solids ratio of about 0.4 or less.

25. The composite material of claim 23, wherein the substrate layer comprises a fiber-cement material.

26. The composite material of claim 23, wherein the functional layer is about 1.25 mm thick and the water drainage time is less than about 120 seconds.

27. The composite material of claim 23, wherein the functional layer further comprises reinforcing fibers.