CN101089324A - Durable building article and method of making same - Google Patents

Durable building article and method of making same Download PDF

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Publication number
CN101089324A
CN101089324A CNA2007101397013A CN200710139701A CN101089324A CN 101089324 A CN101089324 A CN 101089324A CN A2007101397013 A CNA2007101397013 A CN A2007101397013A CN 200710139701 A CN200710139701 A CN 200710139701A CN 101089324 A CN101089324 A CN 101089324A
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CN
China
Prior art keywords
goods
roofing
composite material
cement
cement composite
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Pending
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CNA2007101397013A
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Chinese (zh)
Inventor
M·库曾格
G·布伦顿
H·王
C·江
P·帕格尼斯
I·欣察克
B·斯隆
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James Hardie International Finance BV
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James Hardie International Finance BV
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Publication of CN101089324A publication Critical patent/CN101089324A/en
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/12—Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface
    • E04D1/16—Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface of ceramics, glass or concrete, with or without reinforcement
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B16/00—Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B16/04—Macromolecular compounds
    • C04B16/06—Macromolecular compounds fibrous
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/30—Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00586—Roofing materials
    • C04B2111/00594—Concrete roof tiles
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/30—Nailable or sawable materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/34—Non-shrinking or non-cracking materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/30—Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles
    • E04D2001/304—Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles at roof intersections, e.g. valley tiles, ridge tiles
    • E04D2001/305—Ridge or hip tiles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Civil Engineering (AREA)
  • Architecture (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Roof Covering Using Slabs Or Stiff Sheets (AREA)

Abstract

A durable, nailable, lightweight and fire resistant fiber cement article that can be a cost-effective substitute for conventional building materials is provided. The fiber cement article can be profiled to resemble a roofing article such as a wood shake or slate. The fiber cement article incorporates a hydrophobe and a viscosity enhancing agent that are each selected to control the rate of hydration of the binder. The fiber cement article is durable, is walkable and nailable without cracking during installation and maintains walkablilty after exposure in service.

Description

Durable building goods and the method for making these goods
The application divides an application, and the applying date of original application is that June 21, application number in 2004 are that 200480017232.2 (PCT/US2004/019980), denomination of invention are " durable building goods and the method for making these goods ".
Background technology
Invention field
[0001] in one embodiment, the present invention relates to the fibre reinforced cement goods, more specifically, relate to a kind of lightweight, durable and nailable fibre reinforced cement goods, these fibre reinforced cement goods can conveniently be installed as roof tile.
Description of Related Art
[0002] for example slate and wooden shingle are that two kinds of present world wides use comparatively general roofing goods (roofing article) for natural roofing materials.Yet there is shortcoming in these two kinds of goods.The slate roofing material is being exploited, is being shaped and installing very expensive.Wooden shingle is typically made by mothproof China fir, and owing to the attractive in appearance and easy for installation of them receives an acclaim, but a small amount of supply of high-quality China fir and new building acts restriction are promoting to have the demand of the substitution material of wooden shingle outward appearance.
[0003] therefore, the concrete roof goods, fibre reinforced cement roof tile for example has been developed into the substitute of wooden shingle and slate.Yet the high density that traditional fiber reinforced cement board roofing materials is had makes their extremely difficult nailings.Therefore, they typically are manufactured to the nail hole that has prebored hole.Yet, the shortcoming in prebored hole nail hole is, if preboring nail hole not with roof plate on anchor point align, then the roofing installation personnel does not almost have flexibility, especially so-called " great-jump-forward overburden (skip-sheathing) " wherein covers the mode that sheet material is spaced and makes them can not align with prebored hole.For solving this shortcoming, the roofing installation personnel is filled the interval that great-jump-forward covers roofing usually with extra overlay, and this has further increased roof weight and has prolonged the set-up time.
[0004] when pressure and tension when watt going up, present existing cement composite material and concrete roof tile are also broken easily and are damaged.These concrete and cement roof material, especially thistle tile, innately frangible, and when walking in the above, be easy to split and breakage.Some cementitious composite roofing materialss can have enough initial toughness and break with opposing in installation process, but along with always can become fragile service life, and become and can not walk.In order to solve this difficult problem, many manufacturers recommend to use walking liner (walking pad) at present, walking sheet material, or below roofing materials, use polyurethane foam, help to distribute those because the maintenance purpose need be passed the personnel's on roof weight.Yet these extra protections are inconvenient and implement the cost costliness.
[0005] in addition, traditional concrete or cement composite material roof tile make in the obducent installation of clashing on ridge (hip) or ridge (ridge) zone especially difficult.The roof generally is to make with different gradient (pitch) according to the architectural practice of locality.In order to cover ridge or ridge zone in an opposite direction, the hard concrete tile must be formed several different dihedrals, and in order to cooperate multiple roof style, manufacturer must have multiple dihedral.Other cement composite material roof tile needs location and nailing conscientious and consuming time, and purpose is that ridge is clashed in assurance and the ridge zone is covered suitably.
[0006] roof covering, especially slate, wooden shingle or tile are typically installed in the mode of overlap joint to highest point or ridge from the base of roof line.If the end of roof covering row does not overlap any object, it will with difference thereon the angle of bridge piece angle lie on the roofing slab.This not only can not make us accepting on attractive in appearance, and is clumsy architectural practice, because bridge piece is not supported by first row's object, and is easy to break.For overcoming this defective, for the roofing setter, traditional practice is to get slate, wooden shingle or a tile, cuts from the centre, forms cant strip or eaves shop fixtures layer.Cant strip be placed in each row watt end below, make angle of end row and roof panel orientation, this angle is approximately equal to the angle of bridge piece.Although this operation is reasonably from attractive in appearance and performance standpoint, its waste material and consuming time.
[0007] according to top described, therefore expectation provide a kind of lightweight, middle density is to low-density fibre refinforced cement material, this material can nail on nail and not ftracture, expose to the open air to use and keep its initial toughness and walking afterwards, freeze/melt and keep its bending or hot strength after exposing to the open air, and it is good to raise in the test (wind-uplift test) performance at wind.In addition, also expectation provides a kind of lightweight, durable, nailable roofing goods, the similar natural wooden shingle of these roofing goods, slate or other traditional roofing materials.And expectation provides the fibre reinforced cement roofing goods that can be used as ridge in an opposite direction or ridge overburden or cant strip.
[0008] overcome or improve at least a shortcoming of prior art, or the alternative that provides usefulness is a purpose of the present invention.
Summary of the invention
[0009] on the one hand, the preferred embodiment of the invention provides the prescription of producing cement composite material roofing goods.This prescription comprises hydraulic cementing materials, gather materials, low density additives, fiber (fibers), hydrophobe, selected cement composite material roofing goods that prepare of these components wherein, the rupture modulus of these goods (MoR) is about 1.2MPa/Gpa or bigger with the ratio of modulus of elasticity (MoE), its density is about 1.6g/cm 3Or littler, and these roofing goods can follow closely, and resist stress induced breaking basically.In one embodiment, this prescription further comprises viscosity intensifier.In another embodiment, this prescription further comprises filler and pigment.Preferably, fiber is selected from cellulose fibre, polypropylene fibre, polyester fiber, polyolefine fiber, nylon fiber and their combination.Preferably, hydrophobe is selected from stearate, siloxanes, paraffin, pitch and their combination.
[0010] another aspect, the preferred embodiment of the invention comprise a kind of cement composite material roofing goods, and its rupture modulus (MoR) is about 1.2MPa/Gpa or bigger with the ratio of modulus of elasticity (MoE), and density is about 1.6g/cm 3Or be littler, and can nail and do not cause stress induced breaking.In one embodiment, the roofing goods are roof tile.In another embodiment, the roofing goods are configured to similar wooden shingle or slate.In another embodiment, roof tile has thickness between about 5/16 to 5/8 inch and about 35: 1 aspect ratio.In another embodiment, the roofing goods further comprise at least one back-up coat (reinforcement layer), and it is placed on the roofing goods that meet with stresses in the zone, for example are fit to receive the zone of securing member.Preferably, back-up coat is selected from fleece (fiber mesh), fabric (fabric), film and their combination.Back-up coat is embedded in the roofing goods, or is connected to the low surface of roofing goods.
[0011] on the other hand, the preferred embodiment of the invention comprises cement composite material roofing goods, and it is designed to cover the ridge or the ridge zone in an opposite direction on roof.These roofing goods comprise first, and this first comprises can be followed closely and the cementitious materials of basic cracking resistance; Second portion, this second portion comprise can be followed closely and the cementitious materials of basic cracking resistance.Preferably, first and second parts are coupled to each other by link with being hinged, make that at least a portion can be around the central axis rotation by connector limited.In one embodiment, link comprises pliable and tough reinforcement material, for example fleece.Preferably, link is connected in these two parts the bottom surface of each.In one embodiment, the angle between two parts of roofing goods can be adjusted between about 30 to 180 degree.
The accompanying drawing summary
[0012] Figure 1A and 1B are the schematic diagrames of the different embodiments of cement composite material roofing goods of the present invention.
[0013] Fig. 2 provides the flow chart of the method for the cement composite material roofing goods of making the preferred embodiment of the invention.
[0014] Fig. 3 illustrates the water absorption rate comparison of the cement composite material roofing goods of making according to several different formulations, comprises the prescription of the preferred embodiment of the invention.
[0010] Fig. 4 illustrate preferred embodiment cement composite material roofing goods freeze/melt performance and traditional high density slabstone and shingle roof covering watt freeze/melt performance relatively.
[0015] Fig. 5 is the schematic bottom view of the cement composite material roofing goods of the preferred embodiment of the invention.
[0016] Fig. 6 illustrates to be assembled and is used to cover the sectional view of cement composite material roofing goods that the preferred embodiment in ridge or ridge zone is clashed on the roof.
DESCRIPTION OF THE PREFERRED
[0017] with reference to the accompanying drawings, in this same numeral part of TYP all the time.Some embodiment preferred of the present invention provide new formulation, and this new formulation is used to form the cement composite material building product with improved deflection or hot strength.In one embodiment, this prescription generally includes hydraulic cementing materials, gathers materials low density additives, fiber (fibers), water and preferably can be by heat activated hydrophobic additive.In another embodiment, prescription further comprises viscosity intensifier, pigment and mineral filler.In some embodiments, be made into shapable cement slurry, be shaped to building product, under high temperature and high humility, be cured then according to the formed cement admixture of preferred prescription.Preferably, by partially hydrated and sclerosis, density is less than about 1.6g/cm according to wherein cement 3, preferably less than about 1.2g/cm 3Mode come cured article.Equally preferably, the hardened material ratio that should have rupture modulus (MoR) and a modulus of elasticity (MoE) is at least about 1.2 (MPa/Gpa).This ratio also is measuring of strain and toughness.The inventor be surprised to find middle density that the formed MoR/MoE of having ratio is at least about 1.2MPa/Gpa to low-density fibre refinforced cement goods when being used as roof tile, what can obtain to expect follows closely and walking property performance.In addition, when the aging of product, these materials can keep walking property in use.
[0018] the various component of prescription that is used to form the cement composite material roofing goods of preferred embodiment is described below in more detail.
Hydraulic cementing materials
[0019] hydraulic cementing materials comprises Portland cement (portland cement), high alumina cement, lime, GBFS, cement and gypsum plaster or their mixture.In one embodiment, the prescription of cement composite material goods comprise by butt weight calculate about 15% to 50%, more preferably about 25% to 45% Portland cement (I, II or III type).The inventor sets about from opposite with traditional thinking mode, the hydraulic cementing materials of lower content is joined in the prescription, because the fibre reinforced cement prescription of roofing goods typically has high cement factor, the most typically, calculate by weight approximately between the 50%-80%.Advantageously, the preferable range that the inventor has been found that hydraulic cementing materials content is synergistically in conjunction with other component of this prescription, thereby produces more hard composite material, and its easier nail is therefore more useful on roofing is used.
Gather materials
[0020] gathers materials and comprise siliceous material, for example kieselguhr, Cab-O-sil, rice hull ash, blast-furnace cinder and cigarette ash.In one embodiment, gathering materials has high surface, and selected next and hydraulicity cementitious material reaction, and for example Portland cement generates the durable base-material (matrix) that suitable composite product is expected application.Some roofing goods are used, press butt and calculate, filling a prescription comprises about 15%-50%, the Cab-O-sil of 25%-45% preferably approximately, preferred 200 orders.Gathering materials that other is suitable can comprise; but be not limited to amorphous silica, granulation slag, steel slag, mineral oxide, sand, coal combustion byproduct, limestone, clay, magnesite (magnasite) or dolomite, metal oxide and hydroxide or their mixture.Can based on gather materials with prescription in other component compatibility and/or according to them the influence of overall composite material strength, toughness and density is selected to gather materials.
Low density additives
[0021] low density additives (low density additives) (LDA) can comprise hollow ceramic or glass granules, kieselguhr, synthetic silicic acid hydrate of calcium and coal combustion residue, for example bottom ash, or their mixture in some embodiments.In a preferred embodiment, prescription comprises the LDA that calculates about 1%-50% by butt weight, preferably less than 20%, and more preferably about 2.5%-10%.In one embodiment, LDA comprises having the bottom ash of particle diameter less than about 1/8 inch (3mm), is more preferably less than about 1/16 inch (1.5mm).In another embodiment, LDA comprises having grain density less than about 2.3g/cm 3The lightweight coal ash, its mean particle size is about 100 microns.In another embodiment, before LDA adds mixture, handle LDA with hydraulic material, hydraulic material is silane, wax, stearate or other hydrophobe for example.But one of purpose of LDA is to alleviate the gross weight of composite material and improve its nailability.LDA can be added separately or with other component.In one embodiment, LDA is selected because of itself and hydraulic cementing materials and/or the compatibility of gathering materials, and makes cost optimization, has reduced its negative effect to total composite material strength and water absorption rate simultaneously.
Fiber-like
[0022] fiber can comprise the mixture of short fiber class and long fibre class.The inventor has found that the mixture of these two types of fibers gives the feature combination of formed composite material uniqueness, and this generally is not found in the made material of prior art.This feature is in conjunction with comprising nailability, crack resistance and toughness.
The short fiber class
[0023] in one embodiment, the short fiber class has the length less than about 3mm.Because its weight reduces characteristic and the short fiber class is preferably selected in the influence of nailability and toughness.On some are used, preferred hollow low-density fibre class, for example polymer fiber or cellulose fibre.In a preferred embodiment, the short fiber class comprises bleaching or unbleached Kraft fiber, and it has about 2 to 3mm length with less than about 40 microns diameter.For further reducing the influence of fiber to suction and durability, also can handle fiber with hydrophobic material, this hydrophobic material is silanol for example, wax stearate or other hydrophobic material.
[0024] randomly, can use biocide mass treatment cellulose fibre, this biocide material is compatible with cement material, and will keep the biology of the scheduled time to kill activity in the length of life with any cement products of its manufacturing.Should select to stop effectively and be positioned at fiber or above the contiguous cement matrix or the biocide of near fungi, bacterium, algae or lichens growth.
[0025] such biocide example is described in PCT publication WO 0232830A1, and its full content is introduced at this, as a reference.
The long fibre class
[0026] in one embodiment, the long fibre class is relatively thin and pliability, length is arranged greater than the about fiber of 9mm.Long fibre preferably is selected to the toughness of reinforced composite.Include, but not limited to polymer fiber or glass fiber to increasing the helpful fiber-like of toughness, preferably those with can use cementitious material and/or gather materials system and the compatible fiber of curing.Such fiber can include, but not limited to polyolefin, polyamide, polyester, polypropylene, polymethylpentene, polyacrylonitrile, polyacrylamide, viscose glue, nylon, PVC, PVA, artificial fiber, carbon, glass or their any mixture.Polymer fiber or glass fiber also can be hollow.In one embodiment, long fibre preferably on the length less than between the about 10-20mm, more preferably length is approximately between the 9-15mm.On some roofings were used, long fibre comprised that length is about 20mm, was approximately the 5 daniers polypropylene fibre of (5 daniers are represented great about 5 grams of about 900 meters fiber).Alternatively, fiber can have essentially identical length or width with the goods of finishing, and with goods by pultrusion (pultruded).In some embodiments, can on fiber, use Hydrophilic Surface Treatment, to improve processing and moistening.Also can handle fiber with antioxidant and the reinforcing material of anti-UV.The glass fiber that be fit to use comprises alkali-resistant glass fibre, E-glass fiber, have the glass fiber of polymer coating and have the glass fiber of the coupling agent compatible with the alkaline cement material.Above-mentioned polymerization or glass fiber also can be introduced the biocide material, this biocide material or conduct are to the surfacing of fiber, perhaps, more effectively stop to be positioned on fiber or the contiguous cement matrix or near the growth of fungi, bacterium, algae or lichens as the ingredient of fiber.
Back-up coat
[0027] in some embodiments, the enhancement layer that comprises fleece, fabric or polymer metal film also can be introduced in the cement composite material goods, or be placed on the cement composite material goods, mode is similar to disclosed mode in published U. S. application 20030054123, its full content is introduced at this, as a reference.Back-up coat can comprise any reinforcement material, for example, but is not limited to fiber, polypropylene, nylon, glass, nylon or metal.In one embodiment, back-up coat is net (mesh) or fabric, and it is for weaving or nonwoven, but the polygon or the circular hole that preferably have rule.Net can comprise hollow fibre.Net is preferably had is no more than 20% elongation at break.Net also should have high alkali resistance, high anti-UV, and long-term durability, fire-resistant, and have predetermined hot strength.Enhancement layer also should have high alkali resistance, high anti-UV, and long-term durability, fire-resistant, and have predetermined hot strength.Many polymer are arranged, metal, glass web or other available material can be selected to satisfy these standards.Only for example, have about 4mm to about 6mm aperture, base unit weight (basis weight) is about 50 to 180g/m 2, hot strength is successfully used at per 12 about 350 to 2000N glass of bundle or polymeric web.By layer is embedded goods, or utilize suitable adhesive that it is adhered to the surface, can be back-up coat, for example net is applied to the roofing goods with its original state, for example can use polyurethane binder, hot melt polyurethane adhesive, Gorrilla Glue Or homologue.Back-up coat also can form described goods with cement slurry by pultrusion.Alternatively, back-up coat also can be embedded into whole roofing goods by in the cement layer of co-extrusion pressure.Back-up coat also can be applied to the surface of sclerosis roofing goods with the adhesive that is fit to.
[0028] it is as shown in table 1 that some are suitable as the net materials example of back-up coat.
Net Manufacturer/product Net materials The net size Net weight/area lbs/1000ft 2 Net hot strength (newton/12 bundles)
A Jiebang Fiberglass Co Ltd AR 4×4-100L AR glass 4×4mm 180 1820
B Jiangsu Jiuding CAG80 6-5 The E glass of coating 4×4mm 80 650
C Conwed Plastics R07822 Extruded polypropylene 6.35×6.35 mm 58 355
D Nylon 6.35×6.35 mm
[0029] will give more detailed description as following, in some embodiments of the present invention, back-up coat two the roofing goods that can be used to be articulated and connected along the adjacent side, mode is that goods can be placed neatly along the ridge line on roof or the ridge zone in an opposite direction on roof.
Hydrophobe
[0030] hydrophobe can pass through a lot of diverse ways, reduces the water absorption rate of composite material, for example by the absorption of restriction aqueous water and/or the aquation speed of participation control cement cementitious material.In one embodiment, based on the efficient of water-repelling agent, to the influence of cementitious material aquation, with and dispersiveness select water-repelling agent.Operable water-repelling agent includes, but not limited to soap, preferred stearate, more preferably zinc stearate.The example of the hydrophobic substance that other can be used includes, but are not limited to organosilicon for example silane, siloxanes and estersil (siliconates), paraffin, paraffin wax emulsion, pitch or similar item.In some roofings are used, add water-repelling agent the water absorption rate of composite material can be reduced to be lower than calculate by weight about 10%, even after in water, flooding about 24 hours.Above-mentioned hydrophobic substance can combine with cement matrix is whole.Also hydrophobic substance can be applied to the hydrophilic fibers that is added in the cement matrix, for example cellulose fibre.Also the hydrophobic substance of emulsion, suspension or powder form can be applied to and use said the present invention to fill a prescription on one or more surfaces of formed goods.
Viscosity intensifier
[0031] viscosity intensifier (viscosity enhancing agent) (VEA) is defined as influencing the material of the workability and the moldable property of uncured cement composition at this, this material by with uncured composition in Free water is reversible combines, influence the availability of its Free water and stop the cement hydration effect and bring into play described influence.The example of VEA comprises cellulose ether, clay and other synthetic organic water-soluble macromolecule.In one embodiment, common preferred cellulose ether is used alone or as a mixture the cellulose ether of any following type: methyl hydroxyethylcellulose, hydroxymethyl ethyl cellulose, ethoxy propyl cellulose, hydroxypropyl methylcellulose and hydroxyethylcellulose.In addition, the cellulose ether with other type of same or similar performance also will go on well.On some roofings were used, VEA preferably included hydroxyethylmethyl-cellulose.Suitable VEAs can comprise the Chemical by Dow, the cellulose ether of all manufacturing levels (manufacture grade) that Shin Etsu Chemical and Wolff Walsorode make.In fact, when product touches parts, during products solidifying and in the useful life of product, can reach the waterproof degree and the predetermined hydration rate of expectation by utilizing synergy unique between VEA and the hydrophobe.
Filler
[0032] mineral filler can be added in the prescription, so that specific desired effects to be provided, for example particulate filling, but nailability, the toughness of improvement, or the cost that reduces.Carbonate, borate or metal oxide can be made appropriate filler.In some roofings were used, preferred nominal particle size was about 20 microns or littler calcium carbonate.
Pigment
[0033] in some applications, can use pigment, painted cement composite product.Preferred selection has long-time colour stability and the pigment compatible with selected cementitious material.In some roofings are used, select stable inorganic pigment and the Portland cement-based gelling material of alkali to unite use.Preferably, some pigment are also selected helps retarded cement and controls the cement hydration effect.In some embodiments, preferred pigment comprises transition metal oxide, iron oxide for example, chromium oxide etc.Also can use powdery carbon, as carbon black.In some embodiments, can with do or add pigment with the aqueous suspensions form.In some preferred roofings were used, pigment comprised the carbon black of about 0.35% red ferric oxide and about 1% or the mixture of Black Rouge.
Water
[0034] in some embodiments, provide the required water of proper density and initial properties in the prescription of mixture in about scope of 26% to 32%, an embodiment is about 30%.The percentage composition of water can be calculated as [quality of water/(quality of the quality of water+dried component)] * 100.When calculating metering water, need to measure and deduct then the water that is present in any solids fraction.
[0035] table 1 provides the formula range of the cement composite material goods of certain preferred embodiments of the present invention.
The component title Embodiment #1 (% by weight) Embodiment #2 (% by weight) Embodiment 3 (% by weight)
1 Hydraulic cementing materials About 15%-50% About 25%-45% About 40%
2 Gather materials About 15%-50% About 25%-45% About 40%
3 Low density additives About 0%-20% About 2.5%-10% About 5%
4 Fiber Short About 1%-15% About 1%-11% About 6%
Long About 0.1%-3% About 0.1%-1% About 0.4%
5 Hydrophobe About 0%-2% About 0%-1% About 0.75%
6 Viscosity intensifier About 0.4%-2.5% About 0.5%-2% About 0.8%
Optional member
7 Filler About 0%-20% About 0%-10% About 5%
8 Pigment About 0%-5% About 0%-3% About 1.35%
Table 1: the formula range of the cement composite material goods of certain preferred embodiments of the present invention
[0036] Figure 1A is the schematic diagram according to the formed cement composite material roofing of the prescription of a preferred embodiment of the present invention goods 100.Shown in Figure 1A, roofing goods 100 have the outward appearance of conventional wood panels watt, preferably have about 22 inches length, about 12,7 or 5 inches width, the thickness of 5/16 to 5/8 inch scope.In one embodiment, roofing goods 100 preferably have about 35 to 1 length than wide aspect ratio.
[0037] Fig. 2 B is the schematic diagram according to the formed another kind of cement composite material roofing goods 150 of the prescription of another preferred embodiment of the present invention.Shown in Figure 1B, roofing goods 150 have the outward appearance of traditional slate, preferably have about 22 inches length, about 10 inches width, and about 5/16 inch thickness.Preferably, roofing goods 150 have about 70 to 1 length and width aspect ratio.The fibre reinforced cement roofing goods that also will recognize preferred embodiment can be size miscellaneous, for example have the mean aspect ratio less than about 160, in one embodiment, and less than about 50.
[0038] are lightweights according to the formed roofing goods 100 of above-mentioned prescription and 150, can follow closely, cracking resistance, and have high limit strain and low water absorbable.Freeze/melt and/or periodically wet/dried/charing effect circulation time when the roofing goods are subjected to periodicity, the roofing goods show that preferably substantially the same or improved flexural strength and z-are to hot strength.
[0039] Fig. 2 is the fill a prescription schematic diagram of method 200 of formed roofing goods of the fibre reinforced cement of making the preferred embodiment of the invention.Described method comprises the following steps.
[0040] step 210: form even chylema body
[0041] in step 210, under the concentration level of the described any embodiment of table 1, raw material weighing is put into mixer, blender, or mixer (compounder) or similarly in the machine, for example Eirich  mixer or Hobart  mixer.These materials mix with water, so that the ratio of water and solid is about 35% to 45%, more preferably about 40% to 43%.These components are stirred basic slurry uniformly.
[0042] step 220: form goods
[0043] in step 220, even substantially chylema body is extruded, in molded or mold pressing progressive die tool, mould or any type of molding equipment, or by roll-in (roll press), forms the roofing goods with expectation profile.If use extruding or roll-in, can form batten, and this batten can be cut into fritter subsequently with final roofing article cross sections profile.Alternatively, when slurry was in uncured " initially " state, this batten can be cut into the batten of polylith intermediate length, after goods are cured according to method described herein, subsequently batten was cut into final size.When the bar plate member of batten or intermediate length keeps " initially " state of non-self-supporting, carry out embossing described herein (emboss) at them, solidify and during application step, preferably support them with hardboard or net or bottom die (bottom mold).
[0044] step 230: the adding of the embossing/net of goods
[0045] in step 230, by for example dandy roll press (embossding roll), graining board or any other graining device known in the art are with the optional one or both sides of giving these goods of at least a decorative pattern.In a preferred embodiment, when goods were embossed, fabric (fabric) or net (mesh) were applied to the bottom surface of described goods, make this fabric or net be embedded into the bottom surface of goods.
[0046] step 240: the curing of goods
[0047] in step 240,, make described goods reach the state of a kind of curing and self-supporting by goods are solidified a period of time of preliminary election under predetermined temperature and humidity environment.Such curing result is that aquation takes place cement cementitious material only part.Can be cured for example electrical heating chamber or stove, steam heating chamber or stove, air blast heating clamber or stove by any way.Preferably, described heating furnace or chamber comprise for example steam injection of humidification means, spraying, ultrasonic atomizatio (ultrosonic misters) or similar means.Can pass through heating clamber or stove continuously in batches or with material, finish and solidify or sclerosis.Above-mentioned heating clamber or stove also can be subdivided into the district, and each district has predetermined temperature and humidity, preferred 35 ℃-90 ℃ temperature range, and 10～60% relative humidity.
[0048] can under almost any range temperature that be fit to realize predetermined goods state of cure, density and flexural strength and damp condition, finish the curing of goods.Preferably, goods are cured according to the mode of the MOR/MOE ratio with about at least 1.2 (MPa/GPa).Can separately or be used in combination steam box (steam chest), moisturecuring case, intensity, moistening tank or stove, to obtain realizing that this MOR/MOE is than required temperature and humidity condition.For the prescription described in the embodiment 1, utilize climate cabinet (climate chamber), goods were exposed to the open air under the RH of about 140  and about 40% (relative humidity) about 3.5 hours, under about 113  and about 20%RH, exposed to the open air about 6.5 hours then, solidify this goods.For the prescription described in the embodiment 2, by the sample process being had the gas heating stove in a plurality of zones, the described sample that hardens till obtaining MoR/MoE ratio＞1.2, has temperature, humidity and the time of staying of selection in wherein every district.
[0049] inventor finds, in conjunction with the regioselective aquation treatment effect of VEA and hydrophobe, the partly solidified of the goods that form gives building product some favourable characteristics.By these factors of careful control, the inventor is surprised to find, although have the thickness of low-density and reduction, but can obtain nailability, be suitable for walking, toughness and intensity by the prescription of the preferred embodiment of the invention and according to the formed goods of the method for the preferred embodiment of the invention.Thus formed goods also are found in and can keep in the accelerated aging test or even improved their key performance.
[0050] step 250: the coating of goods
[0051] in step 250, cured plate is cut into the single goods of various sizes by jetting.Coating if desired, on all face of goods then by acrylic based emulsion encapsulant spraying sealing.Use the plate surface temperature that continuous infrared rays (IR) drying stove produces to be enough to drying and to solidify encapsulant, can solidify encapsulant.Selected plate surface temperature depends on concrete encapsulant prescription, yet the plate surface temperature between 200 to 375 ℃ is typical.Coating can be selected to increase the outward appearance of goods, for example by specific color or gloss is provided.Coating also can be selected to reduce or suppress weathering.
[0052] step 260: the packing of goods
[0053] in step 260, goods are stacked, packaged then transportation.In one embodiment, plate is preferably stacked face-to-face and is stacked back-to-back in the layer that replaces, and ties up great about 30 pounds of every bundle with strap.
[0054] Embodiment 1
[0055] in this embodiment, utilize said method 200, make the roofing goods by the slurry that mixes according to prescription as follows.
● about 30.9% cementitious material (II type Portland cement)
● about 30.9% gather materials (200 order silicon sand)
● about 0.4% long fibre (5 daniers * 15mm polypropylene fibre)
● about 5% short fiber (bleached pulp)
● about 25% low density additives (bottom ash, be sieved to excessively＜3mm)
● about 0.75% hydrophobe (zinc stearate)
● about 0.8% VEA (Walocel  hydroxyethylmethyl-cellulose)
● about 0.35% red pigment (red iron oxide)
● about 1% black pigment (carbon black)
● about 5% filler (calcium carbonate-20 micron)
[0056] utilizes and to have that normal business is supply, automatically controlled climate cabinet, goods at about 140  with approximately exposed to the open air about 3.5 hours under the 40%RH, then at about 113  with approximately exposed to the open air about 6.5 hours under the 20%RH, are solidified described goods.
[0042] Embodiment 2
[0057] in this embodiment, utilize said method 200, make the roofing goods by the slurry that mixes according to prescription as follows:
● [0058] about 40.35% cementitious material (II type Portland cement)
● [0059] about 40.35% gather materials (200 order silicon sand)
● [0060] about 0.4% long fibre (5 daniers * 15mm polypropylene fibre)
● [0061] about 5% short fiber (bleached pulp)
● [0062] about 5% low density additives (lightweight fly ass)
● [0063] about 0.75% hydrophobe (zinc stearate)
● [0064] about 0.8% VEA (hydroxyethylmethyl-cellulose)
● [0065] about 0.35% red pigment (red iron oxide)
● [0066] about 1% black pigment (carbon black)
● [0067] about 5% filler (calcium carbonate-20 micron)
[0068] table 2: mechanical performance
Performance (unit) Embodiment 1 Embodiment 2
Rupture modulus MoR (MPa) 3.8 4.2
Modulus of elasticity MoE-(GPa) 2.5 1.8
The MoR/MoE ratio 1.52 2.33
The stove dry density 1.175 1.15
Z is to tensile strength ZDT (MPa) 0.75 0.75
ZDT (MPa) after 80 freeze thawing circulation 1.48 1.48
The %ZDT conservation rate 197％ 197
[0069] table 2 has been summed up the mechanical performance of an embodiment of the formed roofing goods of prescription shown in the embodiment 1.
[0070] according to ASTM D6272, utilize four-point bending test (four point bendtest), measure the rupture modulus and the modulus of elasticity of kiln dried sample.Employed freezing/melt the cyclic test method comprises that (44mm * 44mm) be placed on the limit of shallow plastic containers is so that the about 22mm in bottom is submerged with sample.Then sample is placed in the environmental chamber (environmental chamber), and according to following program cycle (note: following temperature representative sample temperature, but not the temperature of simulation box):
● [0071] kept 1 minute down at about 20 ℃;
● [0072] from approximately+20 ℃ dropping to-20 ℃ ± 1 ℃, the time is not less than about 1 hour and is not more than about 2 hours;
● [0073] approximately-20 ℃ ± 1 ℃ under, kept about 1 hour;
● [0074] from approximately-20 ℃ rise to+20 ℃ ± 1 ℃, the time is not less than about 1 hour and is not more than about 2 hours;
● [0075] approximately+20 ℃ ± 1 ℃ under, kept about 59 minutes
[0076] after 80 circulations, take out sample and also weigh, in about 105 ℃ forced air drying stove dry about 24 hours then, weigh and be placed in the dryer and cool off.By tensile test fixture (tensile test jig) is bonded on each face of sample, the Z-that measures sample is to tensile strength.Before the test, under the relative humidity of about 23 ℃ temperature and 50%,, put into proper mechanical capacity testing equipment (for example Instron test fixture) then, and axially bear a heavy burden, till fracture along the Z axle with about 18 hours of sample balance.
[0077] sample in one embodiment of the invention be configured to z-to tensile strength show not have significantly loss, and the inventor be surprised to find this sample freezing through 80 times/melt circulation after, on intensity, have basic increase, increased about 197%.
[0078] Fig. 4 shows this material and the known high-density fiber refinforced cement plate of prior art, and a kind of performance of the medium density fiber refinforced cement plate that utilizes the commercial offers that polymer latex makes waterproof agent relatively.
Water absorption rate
[0079] after Fig. 5 illustrated and is immersed in various fibre reinforced cement composite samples in the water, quality in time increased.Prescription A is produced according to one embodiment of the invention.Notice that although the cement composite material of handling with polymer latex provides the water proofing property of short time, yet through after 10 hours, its weight increases similar with the fibre reinforced cement composite material that does not adopt the hydrophobe processing fully.
Wind is raised test
[0080] adopt the wind of ICBO AC07. to raise test, the acceptance criterion of special roof system (Acceptance Criteria for Spcial Roofing Systems) the-the 4.3rd joint is estimated according to optimization formula of the present invention and the prepared goods of method.Exemplary as shown in table 3 below.As shown in table 3, the goods of making of the flush type net can bear the highest exerting pressure (calculating with inch water), for preferably, also demonstrate improvement although adhere to net than the goods that those do not have net or fabric reinforcement.
Net Net materials The placement of net Wind is raised performance (inch water)
A AR glass Flush type 22
B The E glass of coating Flush type 15
C Extruded polypropylene Flush type 9
D Nylon Be attached to the surface 8.25
Contrast Do not have Do not have 7
Table 3
[0081] Fig. 5 illustrates the back surfaces 501 of roof covering goods 500, for example the described roof covering goods of Figure 1A and Figure 1B.As shown in Figure 5, when the roofing goods also are in the state of initial slurry shape,, back-up coat is introduced the back surfaces 501 of roofing goods 500 by preferably back-up coat being imbedded in the goods.Alternatively, preferably be in original state when the back side of roofing goods 500, perhaps be in sclerosis, during the self-supporting state, use suitable bonding adhesive or fastener means, back-up coat 502 also may be attached to the back surfaces of roofing goods 500.Back-up coat 502 can comprise a lot of different materials, includes, but not limited to net, fabric or film.
[0082] in some embodiments, preferably back-up coat is placed on that roofing goods 500 tighten device such as nail is driven in the zone of passing these goods.As shown in Figure 5, back-up coat 502 comprises two restraint location 503A being placed on roofing goods 500 and the net on the 503B.This net is driven into the position of passing goods at securing member and advantageously reinforces roofing goods 500, if the overload that is caused by stress causes the appearance of breaking, this will help to keep goods intact.This net also strengthens goods and bears stress from wind, foot-operated, hail and similar factor.
[0083] in a preferred embodiment, roofing goods 500 are about 22 inches long, and back-up coat 502 extends along the back side of roofing goods 500, its extended distance is at restraint location 503A and about 2 inches places above the 503B, and about 8 to 10 inches places below restraint location 503A and the 503B.In another preferred embodiment, roofing goods 500 are approximately 22 inches long, and back-up coat 502 extends along the back side of roofing goods 500, its extended distance is about 2 inches places on restraint location 503A and 503B, and extend to the edge of the roofing goods 500 that are positioned under restraint location 503A and the 503B.In this manner, roofing goods 500 can be resisted the crack propagation (propogation) when being fixed to roof panel, and opposing is applied to breaking that foot-operated, the hail in roofing goods climate exposure zone etc. causes.The roofing goods of this embodiment are also reinforced well, and opposing wind is raised breaking in the test.
[0084] although Fig. 5 has showed a kind of rectangular roofing goods 501, but be to be understood that, the roofing goods of preferred embodiment can be Any shape or profile, and be to be understood that, more than one deck back-up coat can be used on a plurality of positions of roofing goods 500, and described back-up coat can overlap each other, perhaps can not overlap each other.Back-up coat also can be placed on the surface of roofing goods or on the different surfaces.
[0085] Fig. 6 illustrates the sectional view of the roofing article assembly 600 of another embodiment, and this roofing article assembly 600 is configured to cover the ridge or the ridge zone in an opposite direction on roof.As shown in Figure 6, roofing article assembly 600 generally includes at least two kinds of single-piece roofing goods 601A and 601B, and this single-piece roofing goods 601A and 601B are made of roofing wooden shingle, slate or similar articles.Described two kinds of roofing goods 601A, 601B are hinged and link together by engaging 602.Engage 602 and preferably include back-up coat, for example net (mesh), fabric (fabric) or film.Preferably, reinforcing network as described above mode get adhered or imbed the back side of roofing goods.Joint can be along the continuous edge ground or the stretching, extension discontinuously of roofing wooden shingle or slate.In one embodiment, can be with preventing UV and/or waterproof coating or layer, for example organic siliconresin, acrylic silane (silane acrylic) or polyurethane-base coating are handled or dipping back-up coat zone.
[0086] some embodiment preferred of the present invention provide glued prescription (cementitiousformulation), and this gluing prescription comprises cementitious material, gathers materials low density additives, long fibre, short fiber, hydrophobe and viscosity intensifier.In one embodiment, the selected aquation speed of controlling cementitious material of hydrophobe and viscosity intensifier.Preferred binding composition can be used to production lightweight, the durable and roofing goods that can follow closely, for example roof tile.In another preferred embodiment, binding composition is squeezed into the roofing goods of predetermined length and wedge-shaped cross-section, and as eaves shop fixtures layer or cant strip, it is installed in below end row of the roofing goods that are positioned on the roof.In one embodiment, the roofing goods comprise the lightweight binding composition, and its density is less than about 1.2g/cc.In one embodiment, the composition of roofing goods is designed to keep after 80 times freeze/melt circulation or increase its z-to hot strength.In one embodiment, the roofing goods have the MOR/MOE ratio greater than about 1.2MPa/Gpa.In another embodiment, the roofing goods are at its back side, pass on the zone that goods enter into supporting frame around securing member and introduce reinforcing network or fabric.
[0087] preferred embodiment of the invention provides a lot of benefits.Preferred embodiment provides the fibre reinforced cement composite-material formula, described fibre reinforced cement composite-material formula can form and can follow closely, the constructional materials of durable and lightweight, and this constructional materials freezes/melt stability by having especially in conjunction with hydrophobic substance and viscosity intensifier.In addition, embodiment preferred provides the fibre reinforced cement roofing goods of density less than about 1.6gm/cc, and these fibre reinforced cement roofing goods can not broken by nailing, and, even freeze at 80 times/melt circulation after, its z-does not reduce substantially to tensile strength.Preferred embodiment also provides and forms described the nail and the method for durable roof tile.In addition, formed composite material in outward appearance, handle and install similar wood materials.Can under the situation as setting accelerator, polymer latex or silicon ash (silica fume), make formed composite material at the additive of use cost costliness not, to improve the performance of cement composite material.When some embodiment preferred are introduced into the in an opposite direction ridge on roof or ridge overburden, described overburden be durable, be fit to walking, can follow closely, and can be placed on the roofing of any gradient (pitch) or design.
[0088] although the of the present invention basic new feature that the preferred embodiment of the invention is showed, described and points out to be applied to these embodiments, but should be appreciated that with various omissions, replacement and the variation of concrete prescription form, goods and the method for institute's example and can be implemented in the case without departing from the scope of the present invention by those of ordinary skills.Therefore, scope of the present invention should not be limited to foregoing description.

Claims (6)

1. cement composite material roofing goods, described cement composite material roofing goods are used to cover the ridge or the ridge zone in an opposite direction on roof by configuration, and it comprises:
First, this part comprises can follow closely and the cementitious materials of basic cracking resistance;
Second portion, this part comprise can be followed closely and the cementitious materials of basic cracking resistance;
Wherein, described first and second portion interconnect by connecting elements with being hinged in one way, so that at least one part is can be around being pivoted by the central axis that connecting elements limited.
2. described roofing goods of claim 1, wherein said connecting elements comprises pliable and tough reinforcement material.
3. described roofing goods of claim 2, wherein said connecting elements comprises fleece.
4. described roofing goods of claim 3, wherein said connecting elements is connected on the bottom surface of described two-part each part.
5. described roofing goods of claim 2, the angle between wherein said two parts can be adjusted between about 30 to 180 degree.
6. method that forms cement composite material roofing goods, described goods are used to cover the ridge or the ridge in an opposite direction on roof, comprising:
Can follow closely and the contiguous second cement composite material roofing goods of the cement composite material roofing goods of cracking resistance are placed, the side of wherein said two goods is faced mutually; With
Connect the first cement composite material roofing goods and the second cement composite material roofing goods, mode is that the first roofing goods can be around the rotation of second goods.
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