Coated substrate having one or more cross-linked interfacial zones
First Claim
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1. A building article comprising:
- a substrate comprising fiber cement having a porosity of about 2% to about 80% by volume, wherein the fiber cement contains in the range of from about 2 to about 80% by volume of cement, from about 30 to about 70% by volume silica, and from about 1 to about 15% cellulose pulp, and wherein the substrate contains 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 water-based epoxy sealer having 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.
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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.
109 Citations
21 Claims
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1. A building article comprising:
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a substrate comprising fiber cement having a porosity of about 2% to about 80% by volume, wherein the fiber cement contains in the range of from about 2 to about 80% by volume of cement, from about 30 to about 70% by volume silica, and from about 1 to about 15% cellulose pulp, and wherein the substrate contains 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 water-based epoxy sealer having 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. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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- 12. A composite building article having a first zone which comprises fiber reinforced 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 fiber reinforced cement has a porosity of about 2% to about 80% by volume and contains in the range of from about 2 to about 80% by volume of cement, from about 30 to about 70% by volume silica, and from about 1 to about 15% cellulose pulp, and wherein the base coat material comprises a water-based epoxy sealer having 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.
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19. A method of forming a building article, comprising:
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applying a first composition comprising an epoxy-based sealer to an exterior surface of a fiber cement substrate having a porosity of about 2% to about 80% by volume and containing in the range of from about 2 to about 80% by volume of cement, from about 30 to about 70% by volume silica, and from about 1 to about 15% cellulose pulp, wherein a portion of said first composition extends into a subsurface region of the substrate in a controlled manner; and reacting the portion of said first composition with molecules in the subsurface regions in a manner so as to form a cross-linked interfacial zone. - View Dependent Claims (20, 21)
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Specification