Engineered composite building materials and methods of making same
First Claim
1. An engineered composite building material comprising:
- a cementitious substrate having a pre-determined porosity; and
a sub-surface region formed in the substrate, said sub-surface region comprising a cement-polymer matrix configured to reduce moisture absorption of the building material, wherein the cement-polymer matrix comprises a polymeric impregnating agent chemically bonded to hydroxyl functional groups in the substrate, wherein the thickness of the sub-surface region is controlled by the viscosity of the impregnating agent and the porosity of the cementitious substrate, the impregnating agent having a viscosity of less than about 500 cps at 25°
C., wherein the impregnating agent is deposited in the pores and interstices in the cementitious substrate of the sub-surface region, thereby causing the porosity of the sub-surface region to be less than the pre-determined porosity of the cementitious substrate.
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Accused Products
Abstract
An engineered composite building material, such as fiber cement, having one or more engineered sub-surface regions designed to provide the building material with improved moisture ingress resistance, paint adhesion, and other mechanical properties is provided. The sub-surface region has a cement-polymer matrix formed by introducing an impregnating agent into the pores of the substrate. The composite building material may be formed by applying impregnating agents to the subsurface regions of the substrate to form chemical and/or mechanical bonds with the matrix of the building material, the reinforcement fibers, and/or the surface coatings applied to the material. The thickness of the sub-surface regions may be controlled by varying the viscosity and porosity of the building material substrate. The cement-polymer building material has enhanced durability, weather resistance, strength, and stiffness.
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Citations
15 Claims
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1. An engineered composite building material comprising:
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a cementitious substrate having a pre-determined porosity; and a sub-surface region formed in the substrate, said sub-surface region comprising a cement-polymer matrix configured to reduce moisture absorption of the building material, wherein the cement-polymer matrix comprises a polymeric impregnating agent chemically bonded to hydroxyl functional groups in the substrate, wherein the thickness of the sub-surface region is controlled by the viscosity of the impregnating agent and the porosity of the cementitious substrate, the impregnating agent having a viscosity of less than about 500 cps at 25°
C., wherein the impregnating agent is deposited in the pores and interstices in the cementitious substrate of the sub-surface region, thereby causing the porosity of the sub-surface region to be less than the pre-determined porosity of the cementitious substrate. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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Specification