AT17726U1 - Composite building materials with a structured surface - Google Patents

Abstract

Composite building material, comprising a component with at least one irregularly structured surface, which has a large number of elevations and depressions. To increase the robustness and improve the slip resistance, the distance x (measured perpendicularly to the plane X of the component) between the highest point of an elevation and the lowest point of a depression is between 400 μm and 2000 μm and the large number of projections and depressions has an irregular, non-geometric shape, the depressions forming part of the structured surface together forming a network of channels and tracks and the structured surface being hydrophobic.

Description

description

COMPOSITE MATERIALS WITH A STRUCTURED SURFACE

The present invention relates to the field of composite building materials, such as building boards or panels with a structured surface. In particular, the present invention relates to composite building panels with a structured surface and methods for their production and their use as roof, facade, floor covering or ceiling elements.

Components are permanently exposed to a variety of external weather conditions such as rain, frost, UV radiation, etc. These weather influences usually lead to soiling of the products and materials, resulting in an aesthetically unattractive sight. In addition, and more importantly, exposure to the elements typically causes the exposed surface of these building materials to become slippery, e.g. B. by moss and algae growth in connection with humidity and/or frost. Accordingly, there is a serious risk of people slipping and falling, especially with floor coverings and terrace elements, but also when repairing or replacing roof elements.

Various materials and finishes have been tried in the past with varying degrees of success in an effort to produce outdoor building elements with lasting aesthetic appeal and safe use. The most commonly used surface materials are wood, wood-plastic composites and concrete. However, these materials have inherent disadvantages. Wood surfaces have the problem of moss and fungus growth, rot, chipping, splintering and termite infestation. Wood therefore needs to be treated regularly and has a relatively limited lifespan of around 15 years. In addition, the higher quality woods are tropical types of wood that come from the rainforest and are therefore not an environmentally friendly solution. Wood-plastic composite surfaces also suffer from moss and fungus growth, and the polymer component is susceptible to UV degradation. Concrete, on the other hand, has a natural tendency to crack when exposed to adverse and changing weather conditions and moisture.

SUMMARY OF THE INVENTION

Accordingly, it is the aim of the present invention to provide overall aesthetically pleasing and robust composite building materials which are resistant to the deterioration of external influences and which offer increased safety to those who move on the surface of such materials.

In a first aspect, the present invention provides a composite building material that has at least one irregularly structured surface with a plurality of elevations and depressions, characterized in that the distance x (measured perpendicular to the plane X of the component) between the highest point of a peak and the lowest point of a valley is between 400 µm and 2000 µm.

In particular embodiments, the total surface area of the irregularly structured surface is increased by 0.1% to 15% compared to a non-structured surface of the same material and dimensions as the irregularly structured surface.

In particular embodiments, the present invention provides a composite building material that has at least one irregularly structured surface that includes a plurality of elevations and depressions, characterized in that the distance d (measured perpendicular to the plane X of the component) between the highest point of elevation and the lowest point of depression is between 500 µm and 1000 µm, preferably between 600 µm and 800 µm.

In particular embodiments, the present invention provides a composite building material

which has at least one irregularly structured surface comprising a plurality of peaks and valleys, characterized in that the total surface area of the irregularly structured surface is increased by 1% to 0.5% compared to a non-structured surface area of the same material and with the same dimensions how the irregularly structured surface is raised. In further particular embodiments, the present invention provides a composite building material that has at least one irregularly structured surface that includes a plurality of elevations and depressions, characterized in that the total surface area of the irregularly structured surface by 1% to 5% compared to a non structured surface area of the same material and with the same dimensions as the irregularly structured surface.

In a second aspect, the present invention provides a composite building material that has at least one irregularly structured surface with a plurality of elevations and depressions, characterized in that the distance y (measured perpendicular to the X plane of the component) between the highest point a projection and a reference base plane Y has a value between 100 µm and 600 µm and the distance z (measured perpendicular to the plane X of the component) between the deepest point of a depression and a reference base plane Y has a value between 100 µm and 600 µm, the reference base plane Y is chosen parallel to the plane X of the device and intersects the peaks in the middle of the mean distance d between all peaks and all valleys of the structured surface (measured perpendicular to the plane X of the device).

In particular embodiments, the present invention provides a composite building material that has at least one irregularly structured surface with a plurality of elevations and depressions, characterized in that the distance y (measured perpendicular to the X plane of the component) between the highest point of a elevation and a reference base plane Y has a value between 200 µm and 400 µm and the distance z (measured perpendicular to the plane X of the component) between the deepest point of a depression and a reference base plane Y has a value between 200 µm and 400 µm, the reference base plane Y is chosen parallel to the plane X of the device and intersects the peaks and valleys at the midpoint of the mean distance d between all peaks and all valleys of the structured surface (measured perpendicular to the plane X of the device).

In particular embodiments, the present invention provides a composite building material which has at least one irregularly structured surface with a large number of elevations and depressions, characterized in that the surface comprises between 50 and 250 elevations per dm2. In further particular embodiments, the structured surface comprises between 100 and 200 elevations per dm2.

In particular embodiments, the present invention provides a composite building material which has at least one irregularly structured surface which comprises a multiplicity of elevations and depressions, the cross-sectional area being formed by a cross-section of the elevations of the structured surface and a plane Z , is between 200 and 800 mm2 / dm2 of the structured surface and where the plane Z is chosen parallel to the plane X of the device and intersects the ridges in 3/4 of the average distance d between all ridges and all valleys of the structured surface (where the average distance d is the average of the distances measured perpendicular to the plane X of the device).

In particular embodiments, the present invention provides a composite building material which has at least one irregularly structured surface which comprises a multiplicity of elevations and depressions, the total volume of the elevations occurring over the cross-section of these elevations of the structured surface and a plane Z are formed, lies between 50 and 150 mm3 / dm2 of the structured surface, whereby the Z plane is chosen parallel to the X plane of the component and the elevations are in 3/4 of the average

chen distance d between all peaks and all valleys of the structured surface intersects (where the average distance d is the average of the distances measured perpendicular to the plane X of the device).

In a third aspect, the present invention provides a composite building material having at least one irregularly structured surface, the surface being characterized by a developed interface surface area Sdr between 0.001 and 0.050.

In particular embodiments, the present invention provides a composite building material with at least one structured surface, which has a large number of elevations and depressions, the structured surface being hydrophobic.

In particular, the present invention provides a composite building material having at least one structured surface with a plurality of peaks and valleys, wherein the plurality of peaks and valleys has an irregular non-geometric shape.

In particular embodiments, the present invention provides a composite building material which is a cement-bound composite building material or a gypsum-bound composite building material.

In further embodiments, the composite building material is selected from the group consisting of fiber cement-like material, material based on calcium silicate or material based on gypsum.

In particular embodiments, the present invention provides a composite building material which is a facade element, a roof element, a floor element or a ceiling element.

In particular embodiments, the present invention provides a composite building material that is a building board or panel.

In a fourth aspect, the present invention provides a method for producing a composite building material with at least one structured surface having a multiplicity of elevations and depressions, the method comprising the following steps:

a) providing a composite building material and

b) structuring at least one surface of the composite building material by applying a mechanical pressure.

In particular embodiments, the structuring can be carried out by treating at least one surface of the composite building material by brushing, sandblasting, abrasive blasting or any other suitable structuring step with a suitable pressure.

In a fifth aspect, the present invention provides uses of the building material according to the invention as a facade element, roof element, floor element or patio element.

Particular and preferred features of the invention are set out in the independent and dependent claims. Features from the dependent claims can be combined with features from the independent or other dependent claims and/or with features given in the description above and/or below.

The above and other features, characteristics and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate by way of example the principles of the invention. This description is for illustrative purposes only, without limiting the scope of the invention. The reference numbers given below refer to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is an overall view of the top of a structured fiber cement product according to the present invention.

Figure 2 is a top perspective view of a structured fiber cement product according to the present invention.

Figure 3 is a detailed photograph of a textured surface corner of a textured fiber cement product according to the present invention.

Figure 4 is a drawing of a cross-section of a textured surface indicating the following parameters:

- the distance x (measured perpendicular to the plane X of the component) between the highest point of an elevation and the lowest point of a depression;

- the distance y (measured perpendicular to the plane X of the component) between the highest point of an elevation and a reference base plane Y;

- the distance z (measured perpendicular to the plane X of the component) between the deepest point of a depression and a reference base plane Y.

The same reference numbers refer to the same, similar or analogous elements in the different figures.

DETAILED DESCRIPTION OF THE INVENTION

It should be noted that the term "comprising" as used in the claims should not be construed as limited to the means listed below; it does not exclude other elements or steps. It is therefore to be construed as specifying the presence of the specified feature, step or component, but not excluding the presence or addition of one or more other feature, step or component or group thereof. The term "a device comprising means A and B" should therefore not be limited to devices consisting of components A and B only.

Throughout this specification reference is made to "a (number) embodiment" or "a (undefined article) embodiment". Such references mean that a particular feature described in relation to the embodiment is included in at least one embodiment of the present invention. Therefore, the expressions "in a (number) embodiment" or "in an (indefinite article) embodiment" in various places in this specification do not necessarily all refer to the same embodiment, although they could do so. Furthermore, the individual features or characteristics in be combined in one or more embodiments in any suitable manner as would be apparent to one skilled in the art.

The following terms are only used to facilitate understanding of the invention.

As used herein, the singular forms "a" and "the" include both singular and plural references, unless the context clearly dictates otherwise.

As used herein, the terms "comprising", "comprises" and "consisting of" are equivalent to "including", "includes" or "including", "contains" and are inclusive or open and exclude additional parts not listed, Elements or procedural steps are not sufficient.

Mention of ranges of numbers by endpoints includes all numbers and fractions that fall within the respective ranges and the endpoints mentioned.

The term "approximately" as used herein when referring to a measurable value such as a parameter, amount, time duration and the like is intended to include deviations of +/-10% or less, preferably +/- -5% or less, more preferably +/-1% or less, and even more preferably +/-0.1% or less from and to the stated value, to the extent such deviations are suitable for the practice of the disclosed invention. It is understood that the value to which the modifier "approximately" refers also

is specifically and preferably disclosed.

The terms "(fiber) cementitious slurry" or "(fiber) cementitious slurry" referred to herein generally refer to slurries containing at least water, fibers and cement. The fiber cement slurry used in the present invention may also contain other ingredients such as: B. limestone, chalk, quicklime, slaked or hydrated lime, ground sand, quartz sand flour, quartz flour, amorphous silica, condensed silica fume, microsilica, metakaolin, wollastonite, mica, perlite, vermiculite, aluminum hydroxide, pigments, antifoaming agents, flocculants and other additives, but not limited to that.

"Fibers" present in the fiber cement slurry described herein can be, for example, process fibers and/or reinforcing fibers, both of which are organic fibers (typically cellulosic fibers) or synthetic fibers (polyvinyl alcohol, polyacrylonitrile, polypropylene, polyamide, polyester, polycarbonate, etc. ) could be.

The "cement" contained in the fiber cement slurry described herein can e.g. B. but is not limited to portland cement, high alumina cement, iron portland cement, trass cement, metallurgical cement, gypsum, autoclaved calcium silicates and combinations of certain binders.

The terms "predetermined" and "predefined" as used herein with respect to one or more parameters or properties generally mean that the desired value(s) of those parameters or properties are predetermined or has been defined, d. H. before starting the process of manufacturing the products characterized by one or more of these parameters or properties.

The term "cementitious" in the sense of "cementitious product" or "cementitious material" as used herein refers to any product or material containing cement, such as e.g. B. Portland cement, high alumina cement, iron Portland cement, trass cement, metallurgical cement, gypsum, autoclaved calcium silicates and combinations of certain binders. In particular embodiments, the cement in the products of the present invention is Portland cement.

The term "fiber cement product" as used herein refers to products containing at least fiber and cement. The fiber cement products used in the present invention may also contain other ingredients such as: B. limestone, chalk, quicklime, slaked or hydrated lime, ground sand, quartz sand flour, quartz flour, amorphous silica, condensed silica fume, microsilica, metakaolin, wollastonite, mica, perlite, vermiculite, aluminum hydroxide, pigments, antifoaming agents, flocculants and other additives, but not limited to that.

Under a "(fiber cement) board" as used herein and also referred to as a panel or board, is a flat, usually rectangular element to understand a fiber cement panel or board, the or from Fiber cement material is produced. The panel or sheet has two major faces or surfaces, which are the surfaces of greatest area. The panel can be used as an outer surface of walls, both inside and outside a building or structure, e.g. as a facade panel, cladding, etc.

The term "fiber cement sheet" as used herein generally and in particular in the context of the present invention refers to any flat, optionally substantially rectangular sheet or slab consisting essentially of a fiber cement composition and having a thickness of at least about 1 mm, in particular between about 1 mm and 200 mm, in particular between about 2 mm and about 150 mm, more particularly between about 4 mm and about 100 mm, such as between about 8 mm and about 10 mm.

The terms "Hatschek (fiber cement) layer" or a "(Hatschek) fiber cement pro-

duct" as used herein refers to a fiber cement sheet (as defined herein) or fiber cement product made by a Hatschek process comprising at least the following steps:

(i) building up a fiber cement film on a screen, the screen rotating to be in contact with a fiber cement slurry in a vat;

(ii) transferring the fiber cement film from the screen to the felt conveyor, and (iii) collecting the fiber cement film on a collecting roller via the felt conveyor.

In the context of the present invention, the use of the term "fiber cement film" refers to such a thin sheet of fiber cement produced by one or more screens rotating in a fiber cement slurry contained in one or more vats of the Hatschek process the felt conveyor belt is applied. As can be seen from the above, on the one or more wires of the Hatschek machine, a series of thin layers of fiber cement are produced, which are subsequently superimposed and transferred from the one or more wires to the conveyor belt, so that after accumulation on an accumulation roller, a or several uncured Hatschek fiber cement layers are formed. When, in connection with the present invention, a "fiber cement film" is mentioned, it is clear that this term can optionally mean both a single fiber cement film having a thickness between about 0.01 mm and about 0.9 mm, such as in particular between about 0.05 mm and about 0.5 mm, such as between about 0.1 mm and about 0.4 mm, such as about 0.3 mm. (i.e., a thin layer of fiber cement, also called a monolayer, single layer, or primary layer, applied to the felt conveyor belt through a screen from a vat of the Hatschek process), as well as meaning a layer of two or more superimposed layers of fiber cement, each having a thickness between about 0 0.01 mm and about 0.9 mm, such as in particular between about 0.05 mm and about 0.5 mm, such as between about 0.1 mm and about 0.4 mm, such as about 0.3 mm (i.e. two or more superimposed thin layers of fiber cement, applied to the felt conveyor belt by two or more screens from a vat of the Hatschek process). Those skilled in the art will understand that when referring to the methods of the invention in general, depending on the particular configuration of the Hatschek section, both meanings of the term "fiber cement film" as described above are applicable, while in more specific embodiments only one of the two meanings is applicable. For example, in a particular case where only one screen is used in the Hatschek section for carrying out the methods of the invention, "a fiber cement film" as used herein means only a single layer having a thickness between about 0.01 mm and about 0.9 mm applied to the felt conveyor by the wire from a vat of the Hatschek process. On the other hand, when two or more screens are used in the Hatschek section for carrying out the methods of the invention, "fiber cement film" as used herein means a superimposition of two or more individual layers having a thickness between about 0.01 mm and about 0.9 mm , which are applied from the screen from a vat of the Hatschek process to the felt conveyor belt.

The terms "water repellent" or "water repellent treated", used interchangeably herein, refer to (fiber cement) products or fiber cement (film) layers that have been treated with a water repellent or water repellent agent before, during or after their manufacture . In particular, as used herein, a "waterproofed fiber cement product" or "waterproofed fiber cement film" comprises at least one fiber cement top layer that is treated with a waterproofing or waterproofing agent.

The expressions "mass-colored", "mass-colored", "through-colored" in relation to a fiber cement product mean that at least part, preferably all, of the internal structure of this fiber cement product contains at least one, i.e. H. contains one or more pigment(s).

The terms "internal (fiber cement) structure", "internal (fiber cement) structure", "internal (fiber cement) mass" or "internal (fiber cement) mass"" referred to interchangeably herein

are used to denote the fiber cement material present in a fiber cement product that is not visible to the naked eye when the product is viewed from the outside.

The terms "external (fiber-cement) structure" or "external (fiber-cement) surface", referred to interchangeably herein, are used to denote the fiber-cement material that is exposed and visible on the outside of a fiber-cement product .

As used herein, the terms "bulk colored fiber cement products" or "colored fiber cement products" are intended to indicate fiber cement products that are bulk colored (as defined herein).

A "transparent pigment" as used herein is intended to mean a pigment whose pigment particles have the property of transmitting visible light. Thus, as used herein, a "transparent pigment" is a pigment in which the majority of the pigment particles are smaller than the wavelength of visible light.

An "opaque pigment" as used herein means a pigment whose pigment particles do not have the property of transmitting visible light. Thus, as used herein, an "opaque pigment" is a pigment in which the majority of the pigment particles are larger than the wavelength of visible light.

As used herein, a "semiopaque pigment" (also referred to in technical jargon as a semi-transparent pigment) refers to a pigment in which only a specified but significant percentage of the pigment particles have the property of transmitting visible light. Thus, as used herein, a "semiopaque pigment" is a pigment in which a specified but significant percentage of the pigment particles are larger than the visible light wavelength and the remaining percentage of the pigment particles are smaller than the visible light wavelength is.

The term "pigment" as used herein refers to a dry, insoluble, usually powdered, substance which, when suspended in a liquid carrier, becomes a paint, ink, etc. Pigments are typically tiny solid particles that are used to improve appearance through coloring and/or to improve the physical (functional) properties of the paint or ink. Pigments used for coloring are typically 0.2 to 0.4 microns in diameter. Functional pigments are typically 2 to 4 microns in diameter, but can be as large as 50 microns.

As used herein, the term "basic pigment" refers to any pigment (as defined herein) capable of imparting whiteness and/or color to a substance while at the same time contributing significantly to the hiding power of the substance. Basic pigments can be divided into white pigments and color pigments.

As used herein, the term "white pigment" means a base pigment capable of diffusing light and providing whiteness and opacity in smooth or glossy paints or inks. Inorganic white pigments include, but are not limited to, antimony pigments, including antimony white: Sb203; Lead pigments (toxic) including white lead (PbCO3)2.Pb(OH)2; Titanium pigments including titanium white: titanium(IV) oxide TIO2 and; Zinc pigments including Zinc White: Zinc Oxide (ZnO).

The term "colored pigment" referred to herein means a base pigment capable of selectively absorbing light and imparting color to a paint or ink. There are two main types of color pigments: organic pigments, which contain the lighter colors but are not very durable outdoors, and inorganic pigments, which are not as bright as organic colors but are the most durable outdoor pigments.

As used herein, the term "inorganic pigment" refers to naturally occurring mineral colorants, typically metal salts. inorganic pig

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ments are usually oxides or sulfides of one or more metals. Examples of inorganic pigments include, but are not limited to:

- BLUE INORGANIC PIGMENTS:

© Aluminum pigments, including ultramarine: a complex naturally occurring pigment of sulphurous sodium silicate ( Na8-10 Al6Si6024S2-4 );

○ cobalt pigments including cobalt blue and sky blue: cobalt(I) stannate; © Copper pigments including Egyptian Blue: a synthetic pigment of calcium copper silicate (CaCuSi4010) and Han Blue BaCuSi4010; and

[0073] 0 Iron pigments, including Prussian blue: a synthetic pigment from

sene hexacyanoferrate (Fe7(CN) 18);

- GREEN INORGANIC PIGMENTS

0 cadmium pigments including viridian: a dark green pigment composed of hydrated chromium (II) oxide (Cr 2 O 3 ) and cadmium green: a light green pigment composed of a mixture of chrome yellow (CrS) and viridian (Cr 2 O 3 );

© chrome pigments, including chrome green;

- copper pigments, including Paris green: copper(II)acetoarsenite (Cu(C2H3O2)2.3Cu(AsO2)2) and Scheeles green (also called Schloss green): copper arsenite CUHAsO3;

- YELLOW INORGANIC PIGMENTS

© Arsenic pigments including the natural monoclinic arsenic sulfide Orpiment (As2S3);

0 cadmium pigments, including cadmium yellow: cadmium sulfide (CdS);

- chrome pigments, including chrome yellow: natural pigment of lead(I)} chromate (PbCrO4);

o Cobalt pigments, including aureolin (also called cobalt yellow): potassium cobalt nitrite (Na3Co(NO2)6:

[0081] © Iron pigments, including yellow ocher: a naturally occurring clay of hydrated iron oxide (Fe2O3.H2O);

[0082] © Lead pigments, including Naples Yellow; © titanium pigments, including titanium yellow; 0 tin pigments, including mosaic gold: tin sulfide (SnS2);

- ORANGE INORGANIC PIGMENTS

0 cadmium pigments, including cadmium orange: an intermediate between cadmium red and cadmium yellow: cadmium sulfoselenide;

o Chrome pigments, including chrome orange: a naturally occurring pigment mixture of lead (II) chromate and lead (II) oxide. (PoCrO4 + PbO)

- RED INORGANIC PIGMENTS

© Cadmium pigments, including cadmium red: cadmium selenide (CdSe);

0 Iron oxide pigments, including sanguine, caput mortuum, oxide red, red ocher: anhydrous Fe 2 O 3 , burnt sienna: a pigment made by heating raw sienna, Venetian red;

© Lead pigments (toxic) including red lead: lead troxide, Pb30O4;

© Mercury pigments (toxic), including vermilion: synthetic and natural pigment, naturally occurring in the mineral cinnabar; mercury sulfide (HgS);

- BROWN INORGANIC PIGMENTS

Alumina pigments (naturally formed iron oxides) including raw umber: a natural clay pigment composed of iron oxide, manganese oxide and aluminum oxide: Fe 2 O 3 + MnO 2 + nH 2 O + Si + AlO 3 ; Raw Sienna: a naturally occurring tawny pigment derived from limonite clay;

- BLACK INORGANIC PIGMENTS

o Carbon pigments, including carbon black, black ivory, vine black, lamp black;

© Iron pigments, including Fe304; © Titanium pigments: titanium black;

- GRAY INORGANIC PIGMENTS

0 Payne grey: a mixture of ultramarine and black or ultramarine and sienna;

As used herein, the term "organic pigment" refers to synthetic organic dyes; H. Carbon-based molecules made from petroleum compounds, acids, and other chemicals, usually under intense heat or pressure.

Examples of organic pigments include, but are not limited to:

- YELLOW ORGANIC PIGMENTS:

Yellow Lakes, which are transparent pigments used as a yellow tint to mask but not hide other colors, Tartrazine Yellow Lake (also called FD&C Yellow #5 and used as a food coloring), Hansa Yellow and Diarylide Yellow, which are the most common yellow pigments in printing inks. Fluorescent yellow is also used in some specialty applications. Organic yellow pigments are often used as a replacement for chrome yellow;

- ORANGE ORGANIC PIGMENTS:

The most common orange pigment is diarylide orange, a transparent but not very lightfast pigment. Other orange materials are often used where orange pigments are required, e.g. B. DNA Orange, Pyrazolone Orange, Fast Orange F2G, Benzimidazolone Orange HL, and Ethyl Lake Red C;

- RED ORGANIC PIGMENTS:

Reds include Para Red, Toluidine Red, ["Permanent Red "R"], Carmine F.B., Naphthol Red and Rubies, Permanent Red FRC, Bordeaux Red FRR, Ruby Red, Lithol -Red, BON Red, Lithol Ruby 4B, BON Red Brown, Rhodamine 6G, C Lake Red, BON Arylamide Red, Quinacrinone Magenta, Copper Ferrocyanide Pink, Benzimidazolone Carmine and Red, AzoMagenta G , anthraquinone scarlet fever and madder lake;

- BLUE ORGANIC PIGMENTS:

Blue pigments include Phthalocyanine Blue (the most commonly used group of organic blue pigments), PMTA Victoria Blue, Victoria Blue CFA, Ultramarine Blue, Indanthrene Blue, Alkaline Blue and Peacock Blue;

- PURPLE ORGANIC PIGMENTS:

Violet overlaps slightly with some blue-reds (e.g. Benzimidazolone Bordeaux HF 3R (see Benzimidazolone Carmine and Red) and also includes pigments such as PMTA Rhodamine, PMTA Violet (also known as Methyl Violet), Dioxazine Violet (RL ), Carbazole Violet, Crystal Violet, Dioxazine Violet B and Thioindigoid Red;

- GREEN ORGANIC PIGMENTS:

A common set of greens are the phthalocyanine greens and the PMTA greens;

- BROWN ORGANIC PIGMENTS: Brown pigments include Diazo Brown and Benzimidazolone Brown HFR;

As used herein, the terms "filler pigment" or "filler pigment" refer to any pigment (as defined herein) that has a low refractive index or opacity and therefore does not impart color or opacity to a substance. Filler or filler pigments appear transparent in a paint or ink. Filler pigments have a significant positive impact on various paint properties. For example, as described below, mica can improve the water resistance of a film due to its "flat" particle shape and its tendency to align horizontally to the surface in overlapping layers. Examples of filler or filler pigments include barium sulfate, calcium carbonate, magnesium silicate, mica, kaolin (china clay), asbestos, talc, silica/quartz, hydrated alumina, kalunite, pumice, bentonite, vermiculite, and glass beads.

The term "UV curable" refers to a composition that is capable of polymerizing upon application of UV radiation. As a rule, this means at least the presence of photopolymerizable monomers or oligomers, together with photoinitiators and/or photosensitizers.

A "clear coat" or "clear coating composition" as referred to herein is used to refer to a coating formulation or composition that has the property of transmitting light rays through its substance so that surfaces or objects located beyond or behind the coating, e.g. B. coated with such a transparent coating surfaces or objects are clearly visible.

The term "transparent" or "see-through" in relation to a coating composition or a U-coat layer refers to the physical property of transmitting light through the coating without scattering. Transparency can be measured by any method known in the art. For example, a hazemeter measures the transparency, haze, translucency, and total transmission of a coating based on the amount of visible light that is scattered as it passes through the coating. Haze is measured using a wide-angle scattering test, which scatters light in all directions, resulting in a loss of contrast. The percentage of light that deviates from the incident light beam by an average of more than 2.5 degrees during transit is defined as opacity. See-through quality is measured using a narrow-angle scattering test, in which light is scattered in a small area at high concentration. This test measures the clarity with which finer detail can be seen through the tested coating. The turbidimeter also measures total permeability. Total transmittance is the measure of total incident light compared to the light actually transmitted (e.g. total transmittance). So the incident light can be 100% but due to absorption and reflection the total transmittance can be only 94%. The data obtained with the turbidimeter can be transferred to a PC for further data processing in order to ensure a uniform product.

In the context of the present invention, the term "polypropylene" is intended to include any polymer composition containing propylene monomers, either as a homopolymer or as a copolymer with other polyolefins, dienes, or other monomers (such as ethylene, butylene, and the like). The term is also intended to encompass any different configuration and arrangement of the constituent monomers (such as syndiotactic, isotactic, and the like). The term "filaments", "monofilaments", "multifilaments" or "fibers" is therefore intended to include continuous lengths, indeed long strands, threads and the like, of polypropylene homopolymer or copolymer.

The term "slip resistant" is intended to refer to the surface of a material that has been provided with an additional means of increasing slip resistance, thereby increasing the safety of those who work on roofs or other surfaces on which the slip resistant material is installed. walk.

The terms and phrases "surface texture", "texturing", "textured", "embossing", "embossing", "embossed" refer to the result of an embossing process and are intended to refer to the result of an impression produced by printing or a printing process and the process of producing that impression on a recording material or surface

and should therefore be interchangeable.

The invention will now be explained in detail with reference to various embodiments. It goes without saying that each embodiment is presented by way of example only and in no way limits the scope of the invention. In this regard, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For example, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

The present invention provides novel structured composite building products that are mechanically stable and highly resistant to moisture, cracking and abrasion, even under harsh and adverse weather conditions. In particular, the embossed pattern on the building products of the present invention forms a surface texture characterized by outwardly extending protuberances that are distributed, scattered, dispersed, and/or punctuated over at least one of the product's exposed surfaces. Between the extending ridges, the textured surface has a multiplicity of depressions.

The elevations of the structured surface of the building products according to the invention advantageously ensure improved slip resistance. In fact, the embossed pattern on the exposed surface of the building products provides an improved friction surface and thus increases the safety of people entering this surface (e.g. on the surface of a terrace element, a flooring element or a roof element).

The inventors have also surprisingly found that the indentations that are part of the structured surface of the building products of the present invention together form a network of channels and pathways through which water coming from rain or snow, for example, can escape more quickly surface is derived (via the channels and pathways) than non-textured flat surfaces. In this way, the textured surface of the building products of the present invention inherently offers a novel and inventive way to quickly clean the exposed surfaces of building products of excess moisture and/or water. This benefit is further enhanced when the textured surface is treated with a hydrophobing agent. The fact that moisture is removed more efficiently offers the products of the present invention very important advantages, namely protection against efflorescence, algae and/or moss growth. In addition, dirt particles falling on the surface, together with the flow of water through the

transported away by the network of channels and pathways formed by the indentations present in the structured surface. This means that dust and dirt particles have no chance of settling and sticking to the surface itself.

Finally, the products of the present invention are bulk colored composite building products. On the surface of these products, the internal structure and color of the core materials are beautifully displayed. This gives the products a natural yet modern look and also offers the aesthetic advantage that any imperfections or damage that may occur during the life of the products are less visible than with coated products, which are typically not colored in the mass.

In view of the above, it is clear that the present invention provides fiber cement products that are both technically (high weather and moisture resistance and wear resistance with good mechanical strength and impact resistance) and aesthetic (intense but natural-looking color and no color change in damage) are improved.

In a first aspect, the present invention provides a composite building material that has at least one irregularly structured surface that includes a large number of elevations and depressions, characterized in that:

- the distance x (measured perpendicularly to the plane X of the component) between the highest point of a projection and the lowest point of a depression is between 400 µm and 2000 µm and

- the total surface of the irregularly structured surface is increased by 0.1% to 15% compared to a non-structured surface of the same material and with the same dimensions as the irregularly structured surface.

In particular embodiments, the composite building material is a flat, panel-shaped or web-shaped component, such as. B. a slab of slate, paneling, plank, siding or tile. In these particular embodiments, the device has a front major surface that is partially or fully textured and a back major surface that may or may not be textured. In these particular embodiments, the plane X of the device corresponds to the plane parallel to the front and back faces of the device.

In particular embodiments, the present invention provides a composite building material that has at least one irregularly structured surface that includes a plurality of elevations and depressions, characterized in that the distance d (measured perpendicular to the plane X of the component) between the highest point of elevation and the lowest point of depression is between 500 µm and 1000 µm, preferably between 600 µm and 800 µm.

In particular embodiments, the present invention provides a composite building material that has at least one irregularly structured surface with a plurality of elevations and depressions, characterized in that the total surface area of the irregularly structured surface is 1% to 0.5% compared to an unstructured surface of the same material and with the same dimensions as the irregularly structured surface. In further particular embodiments, the present invention provides a composite building material that has at least one irregularly structured surface that includes a plurality of elevations and depressions, characterized in that the total surface area of the irregularly structured surface by 1% to 5% compared to a non structured surface area of the same material and with the same dimensions as the irregularly structured surface.

In particular embodiments, the present invention provides a composite building material which has at least one irregularly structured surface which comprises a multiplicity of elevations and depressions, characterized in that at least one part

and optionally all bumps are not sharp and have a rounded or flat top surface (i.e. the top surface is substantially parallel to the plane X of the device).

In particular embodiments, the present invention provides a composite building material which has at least one irregularly structured surface which comprises a multiplicity of elevations and depressions, characterized in that at least some of the depressions have sharp edges (i.e. approximately perpendicular to plane X of the component).

In a second aspect, the present invention provides a composite building material which has at least one irregularly structured surface with a large number of elevations and depressions, characterized in that:

- the distance y (measured perpendicular to the plane X of the component) between the highest point of an elevation and a reference base plane Y has a value of between 100 µm and 600 µm;

- the distance z (measured perpendicular to the plane X of the component) between the deepest point of a recess and a reference base plane Y has a value between 100 µm and 600 µm,

wherein the reference base plane Y is parallel to the plane X of the device and intersects the peaks and valleys at the midpoint of the mean distance d between all peaks and all valleys on the structured surface (measured perpendicular to the plane X of the device).

In particular embodiments, the present invention provides a composite building material which has at least one irregularly structured surface with a large number of elevations and depressions, characterized in that:

- the distance y (measured perpendicular to the plane X of the component) between the highest point of an elevation and a reference base plane Y has a value of between 200 µm and 400 µm;

- the distance z (measured perpendicular to the plane X of the component) between the lowest point of a recess and a reference base plane Y has a value between 200 µm and 400 µm,

wherein the reference base plane Y is parallel to the plane X of the device and intersects the peaks and valleys at the midpoint of the mean distance d between all peaks and all valleys on the structured surface (measured perpendicular to the plane X of the device).

In particular embodiments, the present invention provides a composite building material that has at least one irregularly structured surface that includes a plurality of elevations and depressions, wherein the total cross-sectional area formed by a cross-section of the elevations of the structured surface and a plane Z , is between 200 and 800 mm2/dm2 of the structured surface, with the plane Z being parallel to the plane X of the device and intersecting the ridges at 3/4 of the average distance d between all the ridges and all the valleys on the structured surface (where the average distance d is the average of the distances measured perpendicular to the plane X of the device).

In particular embodiments, the present invention provides a composite building material which has at least one irregularly structured surface which comprises a multiplicity of elevations and depressions, the total volume of the elevations occurring over the cross-section of these elevations of the structured surface and a plane Z are formed lies between 50 and 150 mm3/dm2 of the structured surface, with the plane Z being arranged parallel to the plane X of the device and intersecting the ridges in 3/4 of the average distance d between all ridges and all valleys on the structured surface ( where the average distance d is the average of the distances,

measured perpendicular to the X plane of the component).

FIG. 4 shows a drawing of a cross section of a structured surface with the following parameters

- the distance x (measured perpendicular to the plane X of the component) between the highest point of an elevation and the lowest point of a depression;

- the distance y (measured perpendicular to the plane X of the component) between the highest point of an elevation and a reference base plane Y;

- the distance z (measured perpendicular to the plane X of the component) between the deepest point of a recess and a reference base plane Y;

- the total cross-sectional area formed by a cross-section of the projections of the structured surface and a plane Z;

- the total volume of bumps formed across the cross-section of these bumps of the textured surface and a Z plane.

The above parameters can be measured using any standard technique known in the art, such as but not limited to microscopy, such as SEM microscopy, 3D profilometer, etc.

In particular embodiments, the present invention provides a composite building material which has at least one irregularly structured surface with a large number of elevations and depressions, characterized in that the surface comprises between 50 and 250 elevations per dm 2 . In further particular embodiments, the textured surface comprises between 100 and 200 elevations per dm2.

In a third aspect, the present invention provides a composite building material having at least one irregularly structured surface, the surface being characterized by a developed interface surface area Sdr between 0.001 and 0.050.

The developed interface surface area Sdr is defined as the ratio between the area of the irregularly textured surface and the area of a flat two-dimensional projection of the irregularly textured surface. This ratio is also referred to in the technical world as the "complexity" of the surface. In the ISO 25178 standard, Sdr is calculated using the following formula:

_ 1 öx(x,y)\” [9z(x,y)\" Z I Oz )+( öy )J-: dxdy

where A is the area of a flat two-dimensional projection of the irregularly textured surface.

In particular embodiments, the present invention provides a composite building material which has at least one structured surface with a large number of elevations and depressions, the structured surface being hydrophobic.

In particular, the present invention provides a composite building material having at least one structured surface with a plurality of peaks and valleys, wherein the plurality of peaks and valleys have an irregular non-geometric shape.

In particular embodiments, the present invention provides a composite building material which is a cement-bound composite building material or a gypsum-bound composite building material.

In further embodiments, the composite building material is selected from the group consisting of fiber cement-like material, calcium silicate-based material or gypsum-based material.

In particular, the present invention provides a composite building material which is a facade element, a roof element, a flooring element or a terrace element.

In particular, the present invention provides a composite building material that is a building board or panel.

In the context of the present invention, fiber cement products are to be understood as meaning cement-bound products which contain cement and synthetic (and optionally natural) fibers. The fiber cement products are made from a fiber cement slurry, which is formed into a so-called "green" fiber cement product and then cured.

Depending on the curing process used, the fiber cement slurry typically consists of water, process or reinforcing fibers which are synthetic organic fibers (and possibly also natural organic fibers such as cellulose), cement (e.g. Portland cement) , limestone, lime, quicklime, slaked or hydrated lime, ground sand, quartz sand flour, quartz flour, amorphous silica, condensed silica fume, microsilica, kaolin, metakaolin, wollastonite, mica, perlite, vermiculite, aluminum hydroxide (ATH), pigments, antifoams, flocculants and /or other additives.

In particular embodiments, the fiber cement products of the present invention at least additionally comprise synthetic fibers.

In particular embodiments, the fiber cement products of the present invention comprise about 0.1 to about 5% by weight, such as in particular about 0.5 to about 4% by weight of synthetic fibers, such as in particular between about 1 to 3% by weight. % synthetic fibres, such as in particular about 2% by weight synthetic fibres, based on the total weight of the fiber cement product.

In further particular embodiments, the synthetic fibers are selected from the group consisting of polypropylene fibers, polyvinyl alcohol fibers, polyacrylonitrile fibers, polyethylene, polyamide fibers, polyester fibers, aramid fibers and carbon fibers. In further particular embodiments, the synthetic fibers in the fiber cement products of the present invention are polypropylene fibers and/or polyvinyl alcohol (PVA) fibers.

In certain embodiments, the synthetic fibers are polypropylene fibers having a thickness of about 70 dtex.

In particular, the synthetic fibers are ground polypropylene fibers having an average length of from about 1 mm to about 2 mm.

In other particular embodiments, the fiber cement formulations of the present invention can also contain natural fibers, such as. B. cellulose fibers are added. In these particular embodiments, the fiber cement products of the present invention can contain about 2 to about 5% by weight, such as in particular about 2 to about 4% by weight cellulose fibers, such as in particular about 3% by weight cellulose fibers, based on the total weight of the fiber cement product. contain. These cellulose fibers can be, for example, kraft softwood cellulose fibers such as bleached kraft softwood cellulose fibers.

In further particular embodiments, additional fibers can be added to the cement formulations, which fibers can be selected from the group consisting of glass fibers, rock wool fibers, slag wool fibers, wollastonite fibers, ceramic fibers and the like. In further particular embodiments, the fiber cement products of the present invention may additionally contain fibrillary fibrids such as, but not limited to, polyolefinic fibrillary fibrids such as "synthetic pulp" in a proportion by weight of about 0.1 to 3%.

[00155] According to particular embodiments, the fiber cement products according to the invention optionally contain further components. These other components in the fiber cement

Products of the present invention may be selected from the group consisting of water, sand, silica sand flour, condensed fumed silica, microsilica, fly ash, ground quartz, ground rock, clays, pigments, kaolin, metakaolin, blast furnace slag, carbonates, pozzolanes, aluminum hydroxide, wollastonite, mica, pearlite, calcium carbonate and other additives (e.g. coloring additives), etc. It is understood that each of these components are present in appropriate amounts which depend on the nature of the specific fiber cement product and can be determined by one skilled in the art. In certain embodiments, the total amount of these other ingredients is preferably less than 70% by weight based on the total original dry weight of the composition.

Other additives that may be included in the fiber cement products of the present invention may be selected from the group consisting of dispersing agents, plasticizers, antifoaming agents and flocculants. The total amount of additives is preferably between about 0.1% and about 2% by weight based on the total original dry weight of the composition.

In particular embodiments, the fiber cement products according to the invention have a thickness between approximately 5 mm and approximately 25 mm, in particular between approximately 5 mm and approximately 20 mm.

In particular embodiments, the fiber cement products according to the invention have a length of between approximately 2 m and approximately 6 m, in particular between approximately 2 m and approximately 4 m, in particular approximately 2.40 m or approximately 3.50 m.

In particular embodiments, the fiber cement products according to the invention have a width of about 1 m to about 4 m, in particular about 1.20 m.

In particular embodiments, the fiber cement products of the present invention may be provided with a coating which may be a colored coating or a clear coating (as defined herein).

In certain embodiments, the colored coating can be a conventional acrylic coating.

In other embodiments, the coating is a conventional clear coat (i.e., non-radiation curable). Suitable conventional clear coats are those with binders that are produced by aqueous free-radical or ionic emulsion polymerization. Acrylic and/or methacrylate (co)polymers are particularly preferred as binders for conventional clear lacquers. These acrylic and/or methacrylic (co)polymers are generally prepared by aqueous free-radically initiated emulsion polymerization of esters of acrylic acid and/or methacrylic acid with C1-C12 alkanols and a small amount of acrylic and/or methacrylic acid as monomers. Esters of acrylic and methacrylic acid with C1-C8 alkanols are particularly preferred; Ethyl acrylate, n-butyl acrylate, ethylhexyl acrylate and methyl methacrylate are particularly preferred. Emulsion polymerization requires the use of surfactants as stabilizers. Nonionic surfactants are preferred. Alcohol ethoxylates are particularly preferred. Conventional coatings with a hydroxyl number (measured according to ISO 4629) of at least 1 are preferred. Hydroxyl numbers of at least 1.5 are particularly preferred. The minimum film formation temperature during drying of the conventional paint is preferably below 60°C.

In addition to the polymeric binders and pigments, the conventional clear coat composition generally also contains customary auxiliaries, e.g. fillers, wetting agents, viscosity modifiers, dispersants, defoamers, preservatives and hydrophobing agents, biocides, fibers and other customary components. Examples of suitable fillers are aluminosilicates, silicates, alkaline earth metal carbonates, preferably calcium carbonate in the form of calcite or lime, dolomite, but also aluminum silicates or magnesium silicates, e.g. talc. The solids content of suitable conventional clear coats is generally in the range from 20 to 60% by weight. The liquid component in conventional clear coats is essentially water and, if appropriate, a water-miscible organic liquid, e.g. an alcohol. the

Conventional coating compositions are applied in a known manner, e.g. by spraying, troweling, curtain coating, squeegeeing, brushing, rolling or pouring onto the cementitious board or by a combination of one or more applications.

In alternative embodiments, the clear coat is a radiation curable clear coat. Radiation curable coatings are known in the art and comprise at least one polymer A having ethylenically unsaturated double bonds which is radiation curable. In principle, possible polymers A for the radiation-curable compositions are all polymers with ethylenically unsaturated double bonds which can enter into a free-radically initiated polymerization when irradiated with UV rays or electron beams. It should be ensured that the content of ethylenically unsaturated double bonds in the polymer is sufficient to ensure effective crosslinking. The content of ethylenically unsaturated double bonds in A is generally in the range of from 0.01 to 1.0 mol/100g A, more preferably from 0.05 to 0.8 mol/100g A, and most preferably from 0.1 to 0.6 mol/100g A

Suitable polymers A are polyurethane derivatives containing ethylenically unsaturated double bonds, such as. B. polyurethane acrylates.

The radiation-curable composition also contains at least one polymer B that can be crosslinked chemically and by radiation. Suitable polymers B are free isocyanate-containing polyurethanes with ethylenically unsaturated double bonds. Polyurethane acrylates with free isocyanate groups are preferred. The reaction of the free isocyanate groups with moisture present in the air takes place at room temperature, especially in areas that are not exposed to the radiation and therefore do not cure completely (backside, edges, cavities in the radiation-curable coating, ...). The free isocyanate content of B, measured according to DIN EN ISO 11 909, is usually between 5 and 20% by weight. Preferably the free isocyanate content of B is between 8 and 20% by weight and preferably between 10 and 18% by weight. The weight ratio of B/A is preferably in the range of 0.03/0.2. A weight ratio of B/A in the range of 0.05/0.1 is particularly preferred. In addition to polymers A and B, the radiation-curable preparations can also contain a compound other than polymer A and polymer B, which has a molecular weight of less than 800 g/mol and can polymerize by a cationic or free-radical route. These compounds generally have at least one ethylenically unsaturated double bond and/or an epoxy group and have a molecular weight of less than 800 g/mol. Such compounds are generally used to set the desired processing consistency of the radiation-curable preparations. This is particularly important if the preparation contains no other diluents such as water and/or inert organic solvents or these only to a minor extent. Such compounds are therefore also referred to as reactive diluents. The proportion of reactive diluents, based on the total amount of (A+B) and the reactive diluent in the radiation-curable preparation, is preferably in the range from 0 to 90% by weight, particularly preferably in the range from 5 to 50% by weight. Preferred reactive diluents are the esterification products of dihydric or polyhydric alcohols with acrylic and/or methacrylic acid. Such compounds are generally referred to as polyacrylates or polyether acrylates. Hexanediol diacrylate, tripropylene glycol diacrylate and trimethylolpropane triacrylate are particularly preferred. The radiation-curable compositions can also contain polymers which have cationically polymerizable groups, in particular epoxy groups. These include copolymers of ethylenically unsaturated monomers, the copolymers containing ethylenically unsaturated glycidyl ethers and/or glycidyl esters of ethylenically unsaturated carboxylic acids as comonomers. These also include the glycidyl ethers of OH-containing polymers, such as OH-containing polyethers, polyesters, polyurethanes and novolaks. Also included are the glycidyl esters of polymers having carboxylic acid groups. If a cationically polymerizable component is desired, the compositions may contain a low molecular weight, cationically polymerizable compound, for example a di- or polyglycerol, instead of or together with the cationically polymerizable polymers.

cidyl ether of a low molecular weight di- or polyol or the di- or polyester of a low molecular weight di- or polycarboxylic acid.

The radiation-curable compositions contain customary auxiliaries such as thickeners, leveling agents, defoamers, UV stabilizers, emulsifiers, surface tension reducers and/or protective colloids. Suitable auxiliaries are well known to those skilled in the art of coatings. Silicones, especially polyether-modified polydimethylsiloxane copolymers, can be used as surface additives to achieve good substrate wetting and good crater protection by reducing the surface tension of the coatings. Suitable stabilizers are typical UV absorbers such as oxanilides, triazines, benzotriazoles (available as Tinuvin'M grades from Ciba Geigy) and benzophenones. These can be used in combination with conventional free-radical scavengers, e.g. B. sterically hindered amines, z. B.

2,2,6,6-Tetramethylpiperidine and 2,6-Di-tert-butylpiperidine (HALS compounds). Stabilizers are generally used in amounts of from 0.1 to 5.0% by weight, preferably from 0.3 to 2.5% by weight, based on the polymerizable components present in the preparation.

If the radiation-curable coating is cured by UV radiation (step f), the preparations to be used contain at least one photoinitiator. A distinction must be made here between photoinitiators for free-radical curing mechanisms (polymerization of ethylenically unsaturated double bonds) and photoinitiators for cationic curing mechanisms (cationic polymerization of ethylenically unsaturated double bonds or polymerization of compounds containing epoxide groups). Photoinitiators are not required for electron beam curable compositions.

Suitable photoinitiators for radical photopolymerization, i.e. polymerization of ethylenically unsaturated double bonds, are benzophenone and benzophenone derivatives such as 4-phenylbenzophenone and 4-chlorobenzophenone, Michler's ketone, a nthrone, acetophenone derivatives such as 1-benzoylcyclohexan-I-ol, 2 -Hydroxy-2,2-dimethylacetophenone and 2,2-dimethoxy-2-phenylacetophenone, benzoin and benzoin ethers such as benzoin methyl ether, benzoin ethyl ether and benzoin butyl ether, benzil ketals such as benzil dimethyl ketal, 2-methyl-[4-(methylthio)phenyl]-2- morpholinopropan-I-one, anthraquinone and its derivatives, such as . Beta-. methyl anthraquinone and tert-butyl anthraquinone, acylphosphine oxides such as 2,4,6-trimethylbenzoyldiphenylphosphine oxide, ethyl 2,4,6-trimethylbenzoylphenylphosphinate and bisacylphosphine oxides. Suitable photoinitiators for cationic photopolymerization, i.e. the polymerization of vinyl compounds or compounds containing epoxide groups, are aryldiazonium salts, such as 4-methoxybenzenediazonium hexafluorophosphate, benzenediazonium tetrafluoroborate and toluenediazonium tetrafluoroarsenate, aryliodonium salts, such as diphenyliodonium hexafluoroarsenate, arylsulfonium salts, such as triphenylsulfonium hexafluorophosphate, benzene and toluene[hexafluorophenylsulfonium]hexadifluorophosphate and bisphenylsulfonium[4-phenylsulfonium]hexafluorobisphenyl , Disulfones such as diphenyldisulfone and phenyl-4-tolyldisulfone, diazodisulfones, imidotriflates, benzoin tosylates, isoquinolinium salts such as NEthoxyisoquinolinium hexafluorophosphate, phenylpyridinium salts such as N-ethoxy-4-phenylpyridinium hexafluorophosphate, picolinium salts such as N-ethoxy-2-picolinium hexafluorophosphate, ferrocenium salts, titanocenes and titanocene salts .

The aforementioned photoinitiators are used in amounts of 0.05 to 20% by weight, preferably 0.1 to 10% by weight and in particular 0.1 to 5% by weight, based on the polymerizable components of the radiation-curable composition used.

Optionally, the clear coat suitable for application to the textured surface of the fiber cement products of the invention contains one or more pigments.

The radiation-curable compositions are in a known manner, for. B. applied by spraying, spatula, doctor blade, brush, roller or pouring onto the cement-bonded board. It is also conceivable that the preparation is applied to the cement board using a hot-melt method or a powder-coating method. The radiation-curable composition is preferably applied by roller coating. The radiation-curable composition is usually applied so that a dry thickness in the range of

10 to 100 μm, preferably from 50 to 80 μm. The application can take place either at room temperature or at elevated temperature, but preferably not above 100.degree. The liquid-coated surface is covered with a radiation-permeable film before the radiation is applied. Care is taken to ensure that there is close contact between the liquid coated plates and the controlled surface layer of the film to remove trapped bubbles and air pockets between the overlying film and the plate by the roller. This film offers protection against the radical chain reaction of oxygen and avoids the use of an inert gas atmosphere during electron beam curing. In addition, this cover sheet has a controlled gloss surface with a predetermined surface finish on the side that comes in contact with the liquid-coated panel surface. Suitable radiation-transmissive films are thin plastic films made from polyester or polyolefins. The controlled surface gloss on the radiation-transmissive sheet can be achieved in a number of ways, e.g. B. by embossing, printing, coating, etching or by using matting additives. In addition, the radiation-transmissive film with its evenly distributed surface micro-roughness can possibly be textured, e.g. B. enables a label.

The radiation-curable coating can be cured by irradiation with UV rays having a wavelength of generally 200 to 600 nm. Suitable examples of UV sources are high and medium pressure mercury, iron, gallium or lead vapor lamps. Particular preference is given to medium-pressure mercury vapor lamps, e.g. B. the CK or CK1 sources from the company 1ST (Institute for Radiation Technology). The radiation dose sufficient for crosslinking is generally in the range from 80 to 3000 mJ/cm2. Any solvents present, in particular water, are dried before curing in a separate drying step, e.g. B. by heating to temperatures in the range of 40 to 80 ° C or by irradiation with IR rays.

In electron beam curing, high-energy electrons (generally 100 to 350 keV, by applying a high voltage to tungsten filaments in a vacuum chamber) are irradiated, and the actual curing step takes place in an inert, oxygen-free atmosphere. After the irradiation, the cover film is removed by peeling it off.

In a fourth aspect, the present invention provides a method for producing a composite building material with at least one structured surface, which comprises a multiplicity of elevations and depressions, the method comprising the following steps:

a) providing a composite building material and

b) texturing of at least one surface of the composite building material by applying mechanical pressure.

In particular embodiments of the methods of the present invention, the composite building material is a cement-bonded composite or a gypsum-bonded composite. In further embodiments, the composite building material is selected from the group consisting of fiber cement-like material, calcium silicate-based material or gypsum-based material.

In particular embodiments, the present invention provides a method for producing a composite building material with at least one structured surface, which comprises a multiplicity of elevations and depressions, the method comprising the following steps:

a) providing a fiber cement slurry, b) preparing a green fiber cement product,

c) texturing at least one surface of the composite building material by applying mechanical pressure, and

d) curing the fiber cement product to obtain a composite building material having at least one textured surface.

In other particular embodiments, the methods of the present invention further include the step of applying a waterproofing agent to the textured surface.

In other particular embodiments, the methods of the present invention further include the step of applying a coating to the structured surface.

In other particular embodiments, the methods of the present invention further include the step of applying a mixture of a coating and a waterproofing agent to the textured surface.

In the first step a) of the methods of the invention, a fiber cement slurry may be prepared using one or more sources of at least cement, water and fiber in the amounts previously disclosed herein. In certain embodiments, these one or more sources of at least cement, water, and pigmented synthetic fibers are operatively connected to a continuous mixing device designed to form a cementitious fiber cement slurry.

Once a fiber cement slurry has been obtained, the manufacture of the fiber cement products can be carried out by any known method. Indeed, in the methods according to the invention, step b) of providing a fiber cement product can be carried out according to any method known in the art of manufacturing fiber cement products, which products comprise at least cement, water and synthetic fibres.

The most widely used process for manufacturing fiber cement products is the Hatschek process, which is carried out on a modified screen cylinder paper machine. Other manufacturing processes are the Magnani process, injection, extrusion, extrusion and others. In particular embodiments, the fiber cement products of the present invention are made by the Hatschek process. The "green" or uncured fiber cement product is optionally post-compacted, typically at pressures ranging from about 22 to about 30 MPa, to achieve the desired density.

The methods according to the present invention may further include the step of cutting the fiber cement products to a predetermined length to form a fiber cement product. Cutting the fiber cement products to a predetermined length can be done by any technique known in the art, such as e.g. B., but not limited to water jet cutting, air jet cutting or the like. The fiber cement products can be cut to any length and width desired, but preferably to the dimensions previously disclosed herein for the products of the present invention. Thus, in certain embodiments, the light colored fiber cement products of the present invention can be cut to specific dimensions to form fiber cement slabs, panels, slabs, siding, planks, tiles, and the like.

One skilled in the art will understand that the methods of the present invention may include additional steps of processing the manufactured fiber cement products.

For example, in certain embodiments, during the methods of the present invention, the fiber cement slurry and/or the fiber cement products may be subjected to various intermediate treatments such as: B. but not limited to treatment with one or more hydrophobing agents, treatment with one or more flocculants, additional or intermediate pressing steps, etc.

Once the fiber cement products are formed, they are trimmed at the lateral edges. Optionally, the edge trims can be recycled by immediately mixing them with the recirculated water and feeding the mixture back to the mixing system.

In particular embodiments, step c) of the method according to the invention, i.e. the texturing, can be carried out by treating at least one surface of the composite building material by brushing, sandblasting, abrasive blasting or another suitable texturing step

done with appropriate pressure.

In step d) of the methods of the present invention, the fiber cement products obtained are cured. After manufacture, the fiber cement products may be allowed to cure for a period of time in the environment in which they were manufactured, or alternatively may be subjected to thermal curing (e.g. by autoclaving or the like).

In particular embodiments, the fiber cement products of the present invention are air cured. This air curing step involves curing the green fiber cement products under ambient conditions for about 2 to 4 weeks, e.g. B. for about 3 weeks.

The inventors have found that air cured fiber cement products, as produced by the methods disclosed herein, perform particularly well, particularly with regard to their mechanical properties, such as impact resistance and mechanical strength. This will become clear from the examples further described here.

In further particular embodiments, the "green" fiber cement products may first be pre-cured in air, after which the pre-cured product is further cured in air to its final strength to give the product its final properties.

In particular embodiments of the present invention, the methods may further comprise the step of thermally drying the fiber cement products obtained. After hardening, the fiber cement product, which is a panel, sheet or board, etc., may still contain a significant amount of water present as moisture. This can be up to 10 or even 15% by weight expressed as the weight of the dry product. Dry product weight is defined as the weight of the product when dried at 105°C in a ventilated oven until a constant weight is reached.

In certain embodiments, the fiber cement product is dried. This drying is preferably carried out by air drying and is terminated when the weight percentage of moisture in the fiber cement product is less than or equal to 8% by weight, even less than or equal to 6% by weight, expressed per weight of dry product, and most preferably between 4 wt% and 6 wt% inclusive.

In a fifth aspect, the present invention provides uses of the fiber cement products according to the present invention as building materials.

In particular embodiments, the present invention provides uses of the fiber cement products according to the present invention as an exterior surface on walls that are internally or externally mounted, e.g. e.g., siding, cladding, etc. In other particular embodiments, the fiber cement products of the present invention may be used for decking, flooring, fencing, and/or decking. In still other embodiments, the fiber cement products of the present invention can be used for roofing applications such as. B. shingles, are used.

In a sixth aspect, the present invention provides uses of the building material according to the invention as a facade element, roof element, floor covering element or covering element.

In a seventh aspect, the present invention provides fiber cement products obtainable by any of the methods of the invention.

The invention will now be explained in detail with reference to the following examples.

From the present description it is apparent that the composite building products according to the invention have an attractive aesthetic appearance due to their structured appearance and their original surface pattern, which is achieved by the presence of a multitude of peaks and valleys (as shown in Figures 1 to 4). Appearance marked

are. Furthermore, in view of the above, it is clear that the present invention provides fiber cement products which are also technically excellent due to their weather and moisture resistance as well as good mechanical strength and impact resistance.

Claims (14)

Expectations 1. Fiber cement composite building board or panel, comprising a component with at least one irregularly structured surface having a plurality of elevations and depressions, characterized in that the distance x (measured perpendicular to the plane X of the building board) between the highest point of an elevation and the lowest point of a depression is between 400 µm and 800 µm and the plurality of peaks and valleys have an irregular, non-geometric shape, the valleys forming part of the structured surface collectively forming a network of channels and pathways. 2. Fiber cement composite building board or panel according to claim 1, characterized in that the total surface area of the irregularly structured surface is increased by 0.1% to 15% compared to a non-structured surface of the same material and with the same dimensions as the irregularly structured surface . 3. Fiber cement composite building board or panel according to claim 1 or 2, characterized in that the distance y (measured perpendicularly to the plane X of the building element) between the highest point of an elevation and a reference base plane Y has a value between 100 µm and 600 µm and the distance z (measured perpendicular to the plane X of the component) between the deepest point of a cavity and a reference base plane Y has a value between 100 µm and 600 µm, the reference base plane Y being chosen parallel to the plane X of the component and the projections in the middle of the average distance d between all elevations and all depressions of the structured surface (measured perpendicular to the plane X of the component). 4. fiber cement composite building board or panel according to any one of claims 1 to 3, characterized in that the irregularly structured surface between 50 and 250 elevations per dm? has, preferably between 100 and 200 elevations per dm? having. 5. Fiber cement composite building board or panel according to any one of claims 1 to 4, characterized in that the cross-sectional area formed by a cross-section of the elevations of the structured surface and a plane Z is between 200 and 800 mm? / dm® structured surface, where the plane Z is chosen parallel to the plane X of the component and intersects the elevations at 3/4 of the average distance d between all elevations and all depressions of the structured surface (where the average distance d is the average of the distances measured perpendicular to the plane X of the component). 6. Fiber cement composite building board or panel according to any one of claims 1 to 5, characterized in that the total volume of the elevation tops formed over the cross section of the elevations and a plane Z is between 50 and 150 mm® / dm? structured surface, where the Z plane is chosen parallel to the X plane of the device and intersects the peaks at 3/4 of the average distance d between all peaks and all valleys of the structured surface (where the average distance d is the average of the distances that measured perpendicular to the X plane of the component). 7. Fiber cement composite building board or panel according to any one of claims 1 to 6, characterized in that the surface has a developed interface surface area Sdr between 0.001 and 0.050. 8. fiber cement composite building board or panel according to any one of claims 1 to 7, characterized in that the structured surface is hydrophobic. 9. fiber cement composite building board or panel according to any one of claims 1 to 8, characterized in that it / it is a facade element, a roof element, a floor element or a ceiling element. 10. A process for producing a fiber cement composite building board or panel according to any one of claims 1 to 9, wherein the board or panel has at least one irregularly structured surface with a large number of elevations and depressions, characterized by a) providing a fiber cement slurry , b) the manufacture of a green fiber cement product using the fiber cement slurry, c) structuring at least one surface of the green fiber cement product by applying mechanical pressure, for example by treating at least one surface of the composite building material by brushing, sandblasting or abrasive blasting, the structuring being carried out to produce a plurality of elevations and depressions of irregular, non-geometric shape and the depressions together form a network of channels and pathways, d) curing the green fiber cement product to obtain a composite fiber cement building board or panel. 11. The method according to claim 10, characterized by the application of a hydrophobing agent to the structured surface. 12. The method according to claim 10 or 11, characterized in that the fiber cement slurry contains at least water, cement and synthetic fibers. 13. Use of a fiber cement composite building board or panel according to one of claims 1 to 9 as a facade element, roof element, floor covering element or ceiling element. 14. Fiber cement composite building board or panel, obtainable by the method according to claims 10 to 12, characterized in that the distance x (measured perpendicularly to the plane X of the building element) between the highest point of an elevation and the lowest point of a depression is between 400 µm and 800 µm and the plurality of peaks and valleys has an irregular non-geometric shape. 3 sheets of drawings