Composite cement article incorporating a powder coating and methods of making same

• US 7,998,571 B2
• Filed: 07/11/2005
• Issued: 08/16/2011
• Est. Priority Date: 07/09/2004
• Status: Active Grant

• Current Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Original Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Inventors: Lyons, David, Sukkar, Theresa
• Primary Examiner(s): Vo; Hai
• Application Number:
  US11/179,355
• Publication Number:
  US 20060024480A1
• Time in Patent Office: 2,227 Days
• Field of Search: 428/312.2, 428/312.4, 428/319.3, 428/319.7, 428/317.9, 428/703, 428/319.1
• US Class Current: 428/319.3
• CPC Class Codes: B32B 13/02 with fibres or particles being present as additives in the layer
• CPC Class Codes: B32B 13/12 of synthetic resin
• CPC Class Codes: B32B 3/26 characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205; characterised by an apertured layer
• 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 41/0045 Irradiation; Radiation, e.g. with UV or IR C04B41/0036 takes precedence
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4545 applied as a powdery material
• CPC Class Codes: C04B 41/4568 Electrostatic processes
• CPC Class Codes: C04B 41/48 Macromolecular compounds
• CPC Class Codes: C04B 41/483 Polyacrylates
• CPC Class Codes: C04B 41/4905 containing silicon
• 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 41/71 at least one coating being an organic material
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• 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 428/24999 Inorganic
• CPC Class Codes: Y10T 428/249991 Synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/249992 : Linear or thermoplastic
• 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 428/31786 : Of polyester [e.g., alkyd, etc.]

Abstract

A cementitious composite article incorporating a powder coating on at least one surface is provided. The composite article includes a surface treatment adapted to facilitate application of the powder coating onto the article. The surface treatment can include modifications to surface porosity, surface, and/or application of a sealer to the surface so as to make the cementitious surface more conducive to powder coating. One method of manufacturing the cementitious composite article includes first applying a sealer coating to a surface of a fiber cement substrate, partially curing the substrate to a gel-like state, applying a powder coating to the article, processing the article to a curing device in which the powder coating and sealer coating are co-cured to form a hardened film.

Claims

1. A cementitious composite article, comprising

a cementitious substrate having a first surface;

a powder coating layer including a plurality of a finely divided, heat fusible material; and

a surface interface comprising a separate sealer coating applied thereon, wherein the surface interface is interposed between the first surface and the powder coating layer, wherein the surface interface consists essentially of inorganic filler in the form of a slurry or powder mixture comprising a cementitious material for modifying the first surface porosity and facilities application of said powder coating layer to the substrate.