Composite fiber cement article with radiation curable component

• US 7,754,320 B2
• Filed: 01/12/2005
• Issued: 07/13/2010
• Est. Priority Date: 01/12/2004
• Status: Active Grant

• Current Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Original Assignee: James Hardie Technology Limited (James Hardie Industries Plc)
• Inventors: Merkley, Donald James, Lyons, David, Sukkar, Theresa
• Primary Examiner(s): Tarazano; D. L
• Assistant Examiner(s): Thompson; Camie S
• Application Number:
  US11/035,386
• Publication Number:
  US 20050208285A1
• Time in Patent Office: 2,008 Days
• Field of Search: 428/292.1
• US Class Current: 428/292.1
• CPC Class Codes: B32B 13/02 with fibres or particles being present as additives in the layer
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/303 Alumina
• 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 20/1029 Macromolecular compounds
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/22 Carbonation resistance
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 40/0003 making use of electric or wave energy or particle radiation
• CPC Class Codes: C04B 40/0064 Processes of the Magnini or Hatscheck type
• 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 41/4578 Coating or impregnating of green ceramics or unset concrete
• CPC Class Codes: C04B 41/4826 Polyesters
• CPC Class Codes: C04B 41/483 Polyacrylates
• CPC Class Codes: C04B 41/4884 Polyurethanes; Polyisocyanates
• CPC Class Codes: C04B 41/63 Macromolecular compounds
• CPC Class Codes: E04C 2/044 of concrete E04C2/049 takes precedence
• CPC Class Codes: E04C 5/073 Discrete reinforcing elements, e.g. fibres
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/249924 : Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 428/249953 : Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249988 : Of about the same composition as, and adjacent to, the void-containing component
• CPC Class Codes: Y10T 428/31511 : Of epoxy ether

Abstract

A composite building article is configured with one or more subsurface interfacial zones provided to improve the durability of the article. Each subsurface interfacial zone is made of a matrix of fiber cement and radiation curable material. The radiation curable material forms an interlocking network with the fiber cement to provide a interfacial zone against ingress of environmental agents that can degrade the article. The number, configuration and distribution of the subsurface interfacial zones can vary dependent on the desired characteristics of the final product. The subsurface interfacial zones also improves the adhesion between exterior coatings and the substrate as the interfacial zones can be integrally formed with the substrate as well as exterior coating layer.

Claims

1. A composite building article having a first zone comprises a fiber cement substrate having a porosity of between about 20%-40% by volume which comprises predominantly fiber cement comprising

about 20-60 weight % cement;

about 0 to 60 weight % silica;

about 0.1 to 15 weight % cellulose fiber; and

about 0-5 weight % of at least one additive;

a second zone which comprises predominantly an EB curable urethane acrylate resin having a solids content of at least 80%, and a subsurface interfacial zone interposed therebetween, the subsurface interfacial zone comprising an interlocking matrix formed of the EB curable urethane acrylate resin and the fiber cement, wherein said interfacial zone is integrally formed with the first and second zones and configured to increase durability of the building article.

2. The composite building article of claim 1, wherein the subsurface interfacial zone contains substantially no catalyst.

3. The composite building article of claim 1, wherein the thickness of the subsurface interfacial zone is controlled by modifying a characteristic selected from the group consisting of the porosity of the first zone, viscosity of the radiation curable component, and combinations thereof.

4. The composite building article of claim 1, wherein the subsurface interfacial zone has a thickness of about 1 μ

m-1,000 μ

m.

5. The composite building article of claim 1, wherein the composite building article is selected from the group consisting of cladding panels, sheets, boards, planks, trims, shakes, and pipes.

6. The composite building article of claim 1, wherein the cement is in the range of about 23.5 to 26.5% of the composition.

7. The composite building article of claim 1, wherein cellulose fibers comprises about 7-9% of the composition.

8. The composite building article of claim 1, wherein the cellulose fibers are unbleached.

9. The composite building article of claim 8, wherein the unbleached cellulose fibers comprise about 11% by weight of the composition.

10. The composite building article of claim 1, wherein the EB curable urethane acrylate resin consists essentially of about 45% difunctional polyester acrylate, about 15% metal acrylate, and about 15% 1,6 hexanediol diacrylate.

11. The composite building article of claim 10, wherein the subsurface interfacial zone is approximately 5 μ

m to 20 μ

m.

12. The composite building article of claim 1, wherein the EB curable urethane acrylate resin consists essentially of about 20% hexafunctional aliphatic urethane acrylate, 14% trifunctional polyester acrylate, and about 14% 3-mercaptopropinoate.

13. The composite building article of claim 12, wherein the subsurface interfacial zone is approximately 5 μ

m to 20 μ

m.

14. A composite building article having a first zone consisting essentially of:

a fiber cement composition consisting essentially of;

20-60 weight % cement;

0 to 60 weight % silica;

0.1 to 15 weight % unbleached cellulose fiber; and

0-5 weight % of at least one additive;

a second zone which comprises predominantly an EB curable urethane acrylate resin; and

a subsurface interfacial zone interposed and integrally formed with the first and second zones and comprising an interlocking matrix formed of the EB curable urethane acrylate resin and the fiber cement, the first zone having a porosity of between about 20%-40% by volume and the EB curable urethane acrylate resin in the subsurface interfacial zone contains substantially no catalyst and is curable primarily by radiation.

15. The composite building article of claim 14, wherein cellulose fibers comprises about 7-9% of the composition.

16. The composite building article of claim 14, wherein the unbleached cellulose fibers comprise about 11% by weight of the composition.

17. The composite building article of claim 14, wherein the at least one additive is selected from the group consisting of flow additive, dispersant, thixotrope, defoamer, and a combination thereof.