Cementitious exterior sheathing product having improved interlaminar bond strength

• US 9,435,124 B2
• Filed: 04/04/2012
• Issued: 09/06/2016
• Est. Priority Date: 11/05/2002
• Status: Expired due to Term

• Current Assignee: Plycem USA, Inc. (Elementia SAB de CV)
• Original Assignee: Plycem USA, Inc. (Elementia SAB de CV)
• Inventors: Bezubic, William Paul Jr.
• Primary Examiner(s): Fox, Charles A
• Assistant Examiner(s): SADLON, JOSEPH
• Application Number:
  US13/439,542
• Publication Number:
  US 20120192517A1
• Time in Patent Office: 1,616 Days
• Field of Search: 522/871, 522/881, 523/091.7, 524/43, 525/78, 527/481, 527/961
• US Class Current: 1/1
• CPC Class Codes: B28B 1/526 by delivering the materials on a conveyor of the endless-belt type
• CPC Class Codes: B28B 1/527 by delivering the materials on a rotating drum, e.g. a sieve drum, from which the materials are picked up by a felt
• CPC Class Codes: B28B 7/46 for humidifying or dehumidifying
• CPC Class Codes: B32B 13/02 with fibres or particles being present as additives in the layer
• CPC Class Codes: B32B 2038/0076 Curing, vulcanising, cross-linking
• CPC Class Codes: B32B 2250/05 5 or more layers
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/10 Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 18/24 Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper , cork
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/00637 as glue or binder for uniting building or structural materials
• CPC Class Codes: C04B 2111/1018 Gypsum free or very low gypsum content cement compositions
• CPC Class Codes: C04B 24/24 Macromolecular compounds C04B24/14 takes precedence; macromolecular compounds comprising sulfonate or sulfate groups C04B24/16
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: C04B 40/006 involving the elimination of excess water from the mixture
• CPC Class Codes: C04B 40/0064 : Processes of the Magnini or Hatscheck type
• CPC Class Codes: C04B 40/0071 : making use of a rise in pressure
• CPC Class Codes: C04B 41/009 : characterised by the material treated
• CPC Class Codes: C04B 41/4578 : Coating or impregnating of green ceramics or unset concrete
• CPC Class Codes: C04B 41/483 : Polyacrylates
• CPC Class Codes: C04B 41/5076 : with masses bonded by inorganic cements sulfur compositions C04B41/5097
• CPC Class Codes: C04B 41/63 : Macromolecular compounds
• CPC Class Codes: E04C 2/04 : of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibresE04C2/26 takes precedence; material or manufacture B28, C04
• CPC Class Codes: E04D 1/16 : of ceramics, glass or concrete, with or without reinforcement
• CPC Class Codes: E04F 13/0733 : for corners
• CPC Class Codes: E04F 13/141 : with an outer layer of concrete E04F13/147 takes precedence
• CPC Class Codes: E04F 13/16 : of fibres or chips, e.g. bonded with synthetic resins , or with an outer layer of fibres or chips E04F13/0864 takes precedence
• CPC Class Codes: E04F 15/10 : of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard , or with a top layer of other materials
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

The present invention provides exterior building products, such as roofing and siding, shake, shingles, siding, sheathing, panels, planks, vertical siding, soffit panels, fencing, decking, fascia, corner posts, column corners and trim boards in which a plurality of cementitious layers are provided with an improved interlaminar bond by employing a resinous bond promoter, a rheological agent, mechanical means to distribute fibers in a direction which is perpendicular to the machine direction so as to bridge between layers in the product, or a combination thereof. These techniques help to increase interlaminar bond strength to improve the mechanical properties of the product. When certain resinous bond promoters are used, the additional benefits of water absorption resistance and pigmentation throughout the product can be provided with minimal expense. Improvements in interlaminar bond strength of about 10 46% were observed with a percent elongation improvement of about 7%.

Claims

1. An exterior siding member comprising a plurality of individual fibercement layers affixed to a rigid support member, wherein the individual fibercement layers comprise a curable non-gypsum cementitious material having fibers therein, and the layers are adhered to one another by one or more of interlaminar bond strength promoters, wherein one of the one or more interlaminar bond strength promoters comprises nano-sized magnesium alumino silicate and an acrylic based resin and water, wherein a ratio of the acrylic based resin to water is 5% to 50%.

2. A cement-containing exterior siding member comprising:

(a) an elongated rigid support member comprising steel, said rigid support member having a wall-facing side and an exterior-facing side and a plurality of fastener receiving holes disposed therethrough; and

(b) a cement-containing layer bonded to said rigid support member, said cement-containing layer comprising a plurality of individual fibercement layers wherein the individual fibercement layers comprise a curable non-gypsum cementitious material having fibers therein, and the fibercement layers are adhered to one another by one or more of interlaminar bond strength promoters, wherein one of the one or more interlaminar bond strength promoters comprises nano-sized magnesium alumino silicate and an acrylic based resin and water, and wherein the cement-containing layer comprises an outwardly facing exterior-facing side.

3. The cement-containing exterior siding member of claim 2, wherein said rigid support member comprises galvanized steel lath or galvanized and perforated steel sheet or plate.

4. The cement-containing exterior siding member of claim 2, further comprising a resinous cement bond promoter to assist in bonding said cement-containing layer to said rigid support member.

5. The cement-containing exterior siding member of claim 2, wherein said cement-containing layer comprises cellulosic fiber, silica sand, portland cement or a combination thereof.

6. A cementitious exterior sheathing product comprising:

(a) a rigid metal support member having a wall-facing side and an exterior-facing side, a nail flange disposed along at least one of its outer edges, and a plurality of perforations defined through the rigid metal support member; and

(b) a cementitious layer bonded to said rigid support member, the cementitious layer extending through the plurality of perforations to lock said cementitious layer to said rigid support member, said cementitious layer comprising a plurality of individual fibercement layers wherein the individual fibercement layers comprise a curable non-gypsum cementitious material having fibers therein, and the fibercement layers are adhered to one another by one or more of interlaminar bond strength promoters, wherein one of the one or more interlaminar bond strength promoters comprises nano-sized magnesium alumino silicate and an acrylic based resin and water, wherein the cementitious layer exhibits a wood grain appearance.

7. A cementitious exterior sheathing product comprising:

(a) a rigid metal support member having a wall-facing side and an exterior-facing side, a nail flange disposed along at least one of its edges, and a plurality of perforations defined through the rigid metal support member; and

(b) a cementitious layer disposed at least on a portion of said rigid support member and being laterally spaced apart from said nailing flange, the cementitious layer extending through the plurality of perforations to lock said cementitious layer to said rigid support member, said cementitious layer comprising a plurality of individual fibercement layers, wherein the individual fibercement layers comprise a curable non-gypsum cementitious material having fibers therein, and the fibercement layers are adhered to one another by one or more of interlaminar bond strength promoters, wherein one of the one or more interlaminar bond strength promoters comprises nano-sized magnesium alumino silicate and an acrylic based resin and water, wherein the cementitious layer exhibits a wood grain appearance, and said metal support member is at least partially embedded within said cementitious layer.

8. An exterior siding member comprising:

(a) a plurality of individual fibercement layers, wherein the individual fibercement layers comprise a curable non-gypsum cementitious material having fibers therein, and the fibercement layers are adhered to one another by one or more of interlaminar bond strength promoters, wherein one of the one or more interlaminar bond strength promoters comprises nano-sized magnesium alumino silicate and an acrylic based resin and water;

(b) a rigid support member having a plurality of perforations defined therethrough, the cementitious material extending through the plurality of perforations to lock said fibercement layers to said rigid support member, the rigid support member also being bonded to one or more of the individual layers of the plurality of fibercement layers, the rigid support member having a wall-facing side and a nailing flange, wherein the nailing flange comprises a fastener receiving portion to receive fasteners for attaching the wall-facing side to a building;

wherein an exterior face of the siding member comprises a press imprinted wood grain texture.