Abrasion resistant coating for stacks of fiber cement siding
First Claim
1. A method of making a fiberboard cement siding product, comprising:
- providing a fiberboard cement substrate,coating a first major surface of the fiberboard cement substrate with a sealer;
coating the exposed surface of the sealer with a primer;
coating the exposed surface of the primer with a decorative coating;
coating the exposed surface of the decorative coating with a topcoat layer comprising a polyurethane dispersion; and
curing the topcoat layer to provide a mar and abrasion resistant coated fiberboard cement siding product;
wherein the curing step comprises a thermal curing process that does not expose the siding to a board surface temperature in excess of 100°
C.;
wherein the fiberboard cement substrate has a density of at least 1 g/cm3 and comprises wood pulp, silica and cement, and the outer topcoat layer has a dry thickness of at least 8 microns.
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Accused Products
Abstract
This invention relates to a novel stack of siding, comprising: first and second coated siding pieces comprising an outer topcoat layer, an inner decorative coating layer and a fiberboard cement substrate layer; and a liner positioned between the first and second coated siding pieces. The siding, during normal transportation and installation, retains an acceptable appearance that is substantially free of viewable scratches or mars. In more preferred embodiments, the outer topcoat layer of the siding has a thickness of at least 8 microns and comprises a polyurethane dispersion. The present invention also provides novel methods of pre-finishing a fiberboard cement siding product, comprising the steps of: providing a fiberboard cement substrate layer; coating a first major surface of the fiberboard cement substrate with a decorative coating; coating the exposed surface of the decorative coating with a topcoat layer; and curing the topcoat layer to provide an abrasion resistant siding. More preferably, the curing step comprises a process that does not require heating the siding to a board surface temperature in excess of 100° C.
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Citations
22 Claims
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1. A method of making a fiberboard cement siding product, comprising:
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providing a fiberboard cement substrate, coating a first major surface of the fiberboard cement substrate with a sealer; coating the exposed surface of the sealer with a primer; coating the exposed surface of the primer with a decorative coating; coating the exposed surface of the decorative coating with a topcoat layer comprising a polyurethane dispersion; and curing the topcoat layer to provide a mar and abrasion resistant coated fiberboard cement siding product;
wherein the curing step comprises a thermal curing process that does not expose the siding to a board surface temperature in excess of 100°
C.;wherein the fiberboard cement substrate has a density of at least 1 g/cm3 and comprises wood pulp, silica and cement, and the outer topcoat layer has a dry thickness of at least 8 microns. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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22. A method of making a stack of fiberboard cement siding products, comprising:
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preparing two or more coated fiberboard cement siding products, the method comprising; providing a fiberboard cement substrate; optionally coating a first major surface of the fiberboard cement substrate with one or more layers comprising a sealer, a primer, or both; coating one or more layers of a decorative coating to the outermost surface of the optionally coated fiberboard cement substrate layer; coating the exposed surface of the one or more layers of a decorative coating with a topcoat layer comprising a polyurethane dispersion; curing the topcoat layer to provide a mar and abrasion resistant coated fiberboard cement siding product;
wherein the curing step comprises a thermal curing process that does not expose the siding to a board surface temperature in excess of 100°
C.; andstacking the two or more coated fiberboard cement siding products to form a stack; wherein the fiberboard cement substrate has a density of at least 1 g/cm3 and comprises wood pulp, silica and cement, and the outer topcoat layer has a dry thickness of at least 8 microns.
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Specification