NZ733584B2 - Ink-jet printing on fiber cement products - Google Patents
Ink-jet printing on fiber cement products Download PDFInfo
- Publication number
- NZ733584B2 NZ733584B2 NZ733584A NZ73358416A NZ733584B2 NZ 733584 B2 NZ733584 B2 NZ 733584B2 NZ 733584 A NZ733584 A NZ 733584A NZ 73358416 A NZ73358416 A NZ 73358416A NZ 733584 B2 NZ733584 B2 NZ 733584B2
- Authority
- NZ
- New Zealand
- Prior art keywords
- fiber cement
- ink
- coating composition
- cement products
- pigment
- Prior art date
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- 238000007641 inkjet printing Methods 0.000 title claims abstract description 44
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- 238000000034 method Methods 0.000 claims abstract description 64
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- 239000001023 inorganic pigment Substances 0.000 claims description 22
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- KRHYYFGTRYWZRS-UHFFFAOYSA-M fluoride anion Chemical compound [F-] KRHYYFGTRYWZRS-UHFFFAOYSA-M 0.000 description 1
- 229920002313 fluoropolymer Polymers 0.000 description 1
- 239000004811 fluoropolymer Substances 0.000 description 1
- 239000010881 fly ash Substances 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 235000013305 food Nutrition 0.000 description 1
- VZCYOOQTPOCHFL-UHFFFAOYSA-N fumaric acid Chemical group OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 1
- 239000001530 fumaric acid Chemical group 0.000 description 1
- 230000000855 fungicidal Effects 0.000 description 1
- 239000000417 fungicide Substances 0.000 description 1
- 229910052733 gallium Inorganic materials 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- NSGJBNFQQJBZHT-UHFFFAOYSA-N iron(3+);manganese(2+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[Mn+2].[Mn+2].[Fe+3].[Fe+3] NSGJBNFQQJBZHT-UHFFFAOYSA-N 0.000 description 1
- KFZMGEQAYNKOFK-UHFFFAOYSA-N iso-propanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 1
- AWJUIBRHMBBTKR-UHFFFAOYSA-O isoquinolin-2-ium Chemical class C1=[NH+]C=CC2=CC=CC=C21 AWJUIBRHMBBTKR-UHFFFAOYSA-O 0.000 description 1
- 239000002655 kraft paper Substances 0.000 description 1
- 229940035105 lead tetroxide Drugs 0.000 description 1
- YEXPOXQUZXUXJW-UHFFFAOYSA-N lead(II) oxide Inorganic materials [Pb]=O YEXPOXQUZXUXJW-UHFFFAOYSA-N 0.000 description 1
- 235000010187 litholrubine BK Nutrition 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- 235000012245 magnesium oxide Nutrition 0.000 description 1
- 235000012243 magnesium silicates Nutrition 0.000 description 1
- 239000011976 maleic acid Chemical group 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 229910052753 mercury Inorganic materials 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 125000005397 methacrylic acid ester group Chemical group 0.000 description 1
- 125000005395 methacrylic acid group Chemical group 0.000 description 1
- 239000002557 mineral fiber Substances 0.000 description 1
- 239000003607 modifier Substances 0.000 description 1
- 150000002763 monocarboxylic acids Chemical group 0.000 description 1
- 125000004108 n-butyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 239000002736 nonionic surfactant Substances 0.000 description 1
- 229920003986 novolac Polymers 0.000 description 1
- 229920000620 organic polymer Polymers 0.000 description 1
- 229910052958 orpiment Inorganic materials 0.000 description 1
- 239000003002 pH adjusting agent Substances 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
- 239000010893 paper waste Substances 0.000 description 1
- 230000037361 pathway Effects 0.000 description 1
- 238000000059 patterning Methods 0.000 description 1
- 230000000149 penetrating Effects 0.000 description 1
- MKTRXTLKNXLULX-UHFFFAOYSA-P pentacalcium;dioxido(oxo)silane;hydron;tetrahydrate Chemical compound [H+].[H+].O.O.O.O.[Ca+2].[Ca+2].[Ca+2].[Ca+2].[Ca+2].[O-][Si]([O-])=O.[O-][Si]([O-])=O.[O-][Si]([O-])=O.[O-][Si]([O-])=O.[O-][Si]([O-])=O.[O-][Si]([O-])=O MKTRXTLKNXLULX-UHFFFAOYSA-P 0.000 description 1
- 239000002304 perfume Substances 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 125000001997 phenyl group Chemical group [H]C1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 description 1
- 239000011505 plaster Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 1
- 229920005862 polyol Polymers 0.000 description 1
- 150000003077 polyols Chemical class 0.000 description 1
- 229920002689 polyvinyl acetate Polymers 0.000 description 1
- 239000011118 polyvinyl acetate Substances 0.000 description 1
- 229920000036 polyvinylpyrrolidone Polymers 0.000 description 1
- 235000013855 polyvinylpyrrolidone Nutrition 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 229910001950 potassium oxide Inorganic materials 0.000 description 1
- 230000002335 preservative Effects 0.000 description 1
- 239000003755 preservative agent Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- DNIAPMSPPWPWGF-UHFFFAOYSA-N propylene glycol Substances CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 description 1
- 230000001681 protective Effects 0.000 description 1
- 239000008262 pumice Substances 0.000 description 1
- 239000003638 reducing agent Substances 0.000 description 1
- 230000001105 regulatory Effects 0.000 description 1
- 239000011435 rock Substances 0.000 description 1
- 238000007761 roller coating Methods 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N silicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- 150000004760 silicates Chemical class 0.000 description 1
- 229910001948 sodium oxide Inorganic materials 0.000 description 1
- 229910052596 spinel Inorganic materials 0.000 description 1
- 239000011029 spinel Substances 0.000 description 1
- 229940071182 stannate Drugs 0.000 description 1
- 125000005402 stannate group Chemical group 0.000 description 1
- QXKXDIKCIPXUPL-UHFFFAOYSA-N sulfanylidenemercury Chemical compound [Hg]=S QXKXDIKCIPXUPL-UHFFFAOYSA-N 0.000 description 1
- 230000002123 temporal effect Effects 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 150000003568 thioethers Chemical class 0.000 description 1
- 229910001929 titanium oxide Inorganic materials 0.000 description 1
- 150000003918 triazines Chemical class 0.000 description 1
- WGLPBDUCMAPZCE-UHFFFAOYSA-N trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 description 1
- OFOZWFGJJSDVIP-UHFFFAOYSA-N triphenylsulfanium;hexafluorophosphate Chemical compound F[P-](F)(F)(F)(F)F.C1=CC=CC=C1[S+](C=1C=CC=CC=1)C1=CC=CC=C1 OFOZWFGJJSDVIP-UHFFFAOYSA-N 0.000 description 1
- UJMBCXLDXJUMFB-UHFFFAOYSA-K trisodium;5-oxo-1-(4-sulfonatophenyl)-4-[(4-sulfonatophenyl)diazenyl]-4H-pyrazole-3-carboxylate Chemical compound [Na+].[Na+].[Na+].[O-]C(=O)C1=NN(C=2C=CC(=CC=2)S([O-])(=O)=O)C(=O)C1N=NC1=CC=C(S([O-])(=O)=O)C=C1 UJMBCXLDXJUMFB-UHFFFAOYSA-K 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- 235000013799 ultramarine blue Nutrition 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- BZHJMEDXRYGGRV-UHFFFAOYSA-N vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 1
- 239000004034 viscosity adjusting agent Substances 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
- 239000001052 yellow pigment Substances 0.000 description 1
- 238000004383 yellowing Methods 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- XYLMUPLGERFSHI-UHFFFAOYSA-N α-Methylstyrene Chemical compound CC(=C)C1=CC=CC=C1 XYLMUPLGERFSHI-UHFFFAOYSA-N 0.000 description 1
Abstract
The present invention relates to processes for producing fiber cement products as well as to the fiber cement products obtainable therewith. More specifically, the present invention relates to fiber cement products that are suitable for being subjected to ink-jet printing, which fiber cement products at least comprise on their outer surface one or more cured layers of a first coating composition, which at least comprises a binder and an alkali resistant pigment and which is characterized by an effective pigment volume concentration of between 60% and 80%. The invention further provides processes for producing such fiber cement products. Moreover, the present invention provides processes for producing ink-jet printed fiber cement products for protecting the the product from weathering and humidity, preventing ink bleeding, and to help protect the product during transport and installation to provide a quality ink-jet printed fiber cement products obtainable therewith. The present invention further relates to various uses of these fiber cement products, in particular as building materials. s at least comprise on their outer surface one or more cured layers of a first coating composition, which at least comprises a binder and an alkali resistant pigment and which is characterized by an effective pigment volume concentration of between 60% and 80%. The invention further provides processes for producing such fiber cement products. Moreover, the present invention provides processes for producing ink-jet printed fiber cement products for protecting the the product from weathering and humidity, preventing ink bleeding, and to help protect the product during transport and installation to provide a quality ink-jet printed fiber cement products obtainable therewith. The present invention further relates to various uses of these fiber cement products, in particular as building materials.
Description
INK-JET PRINTING ON FIBER CEMENT PRODUCTS
Field of the invention
The present invention relates to processes for producing fiber cement products as well as to the fiber
cement products obtainable therewith. More specifically, the present invention relates to fiber
cement products that are suitable for being subjected to ink-jet ng as well as to processes for
producing such fiber cement products. Moreover, the present invention provides processes for
producing ink—jet d fiber cement products and ink-jet d fiber cement products able
therewith. The present invention further relates to various uses of these fiber cement products, in
particular as building materials.
Background of the invention
Fiber cement ts are well known and widely used as building als. In order to protect
these als from potential transport and installation damages as well as defects due to
weathering and humidity, one or more coating layers are often applied on the outer surface during
production. In addition, colored coatings were developed to provide fiber cement products with an
esthetically d look at the outer surface.
However, it would further be desirable to produce fiber cement products provided with a decorative
design pattern, an advertising n and/or an identification print on the outer surface.
Ink—jet printing with traditional solvent-based or water-based pigmented inks is a known method for
directly patterning and fabricating patterns without the need for masks. While this s has been
widely used for producing decorative and advertising patterns directly onto on s such as
ceramics and glass, this was up to now not possible with fiber cement products because of the
inherent heterogenic composition and surface ess of fiber cement. Indeed, ink—jet printing
performed directly onto the surface of a fiber cement object with traditional solvent-based or water-
based pigmented inks resulted up to now in ink bleeding and thereby substantially reduced the print
quality by causing jagged edges and even undesirable ink stains.
Summary of the ion
An object of the present ion is to provide improved fiber cement products, as well as processes
for the production thereof, which ts are suitable for being subjected to ink—jet printing with
traditional solvent-based or water-based pigmented inks, i.e. without ing in the above
described undesirable consequences of ink spreading throughout the fiber cement structure.
In this regard, the present inventors have developed novel and improved fiber cement products
that can be ink-jet printed with high efficiency and performance.
In particular, it was found that by providing fiber cement products with at least one coating
layer, comprising a binder and a t, which layer is characterized by a pigment volume
concentration (PVC) of higher than about 40%, ink-jet printing can be performed without
encountering any of the above-stated issues. The inventors have found that this is due to the
fact that the coating layer as described in the present invention has an improved (i.e. increased)
porosity for t ink compositions in comparison with the outer surface of known coated and
uncoated fiber cement products. By being able to absorb and capture the ink composition
relatively quickly after ink-jetting, the coating layer of the products of the invention ts
this ink composition from spreading out over the surface of the fiber cement product. The
ors have found that this effect is ularly observed when making use of prime
pigments (as d herein), such as for example TiO2, wherein these prime pigments are
present in an effective pigment volume concentration (as defined herein) of at least about 40%.
In a first aspect, the present invention provides an ink-jet printed fiber cement product, which
ink-jet printed fiber cement product at least comprises on at least part of its outer surface: one
or more cured layers of a first coating ition, at least comprising a binder and an alkali
ant pigment, wherein said first coating composition is characterized by an effective
pigment volume concentration between 60 and 80%, wherein the effective pigment volume
concentration can be calculated via the following mathematical formula: “effective pigment
volume concentration” (expressed in %) = “effective PVC” ssed in %) = (volume of
prime pigments)/(volume of prime pigments + volume of solid binder(s)) * 100 (expressed in
%); and a dried ink print applied on top of said one or more cured layers of a first coating
composition
In a second aspect, the t invention provides a process for producing a fiber cement
product, said process comprising: providing a fiber cement product; ng to at least part of
the outer e of said fiber cement one or more layers of a first coating composition at least
sing a binder and an alkali-resistant pigment, wherein said first coating composition is
characterized by an effective pigment volume concentration between 60 and 80%, n the
effective pigment volume concentration can be calculated via the following mathematical
formula: “effective pigment volume concentration” (expressed in %) = “effective PVC”
ssed in %) = (volume of prime pigments)/(volume of prime pigments + volume of solid
(s)) * 100 (expressed in %); curing said one or more layers of said first coating
composition so as to obtain a fiber cement product suitable for being ted to inkjetprinting
; applying an ink print on top of said one or more cured layers of said first coating
composition by means of an inkjet-printer; and drying said ink print, so as to obtain an ink-jet
printed fiber cement t.
Also disclosed herein are fiber cement products suitable for being subjected to inkjet-printing,
which fiber cement products at least comprise on at least part of their outer surface one or more
cured layers of a first coating composition, which composition at least comprises a binder and
a pigment and is characterized by a pigment volume concentration (PVC) of at least about 40%,
ularly between about 40% and about 80%, such as between about 40% and about 70%,
more particularly between about 40% and about 60%. In further particular embodiments, the
first coating composition of the fiber cement products suitable for being subjected to inkjetprinting
is characterized by a pigment volume tration of at least about 50%, more
particularly between about 50% and about 80%, such as between about 50% and about 70%,
most particularly between about 50% and about 60%. In yet further particular embodiments,
the first coating composition of the fiber cement ts suitable for being subjected to inkjetprinting
is characterized by a pigment volume concentration of n about 40% and about
50%, more particularly between about 45% and about 50%, such about 46%.
In particular embodiments, the binder in the first coating composition provided on the outer
surface of the fiber cement products according to the present invention is an acrylic polymer.
In further particular embodiments, the acrylic polymer is chosen from the group consisting of
styrene acrylic, siloxane acrylic, epoxy acrylic, polyester c, polyuria acrylic and urethane
acrylic.
r disclosed herein are processes for producing fiber cement products suitable for being
subjected to ink-jet printing, said processes at least comprising the steps of:
- ing a fiber cement product,
- applying to at least part of the outer e of the fiber cement product one or more layers of
a first coating ition, which composition at least comprises a binder and a pigment and
is characterized by a pigment volume concentration (PVC) of higher than about 40%, and
- curing the one or more layers of the first coating composition so as to obtain a fiber cement
product suitable for being subjected to inkjet-printing.
In particular embodiments of these processes for producing fiber cement ts suitable for
being subjected to ink-jet printing, the first coating composition is terized by a pigment
volume concentration of at least about 50%, more particularly between about 50% and about
80%, such as between about 50% and about 70%, most particularly between about 50% and
about 60%.
In further particular embodiments of these processes for producing fiber cement products
suitable for being subjected to ink-jet printing, the binder in the first coating composition is an
acrylic polymer. In further particular ments, the acrylic polymer is chosen from the
group consisting of styrene acrylic, siloxane acrylic, epoxy c, polyester acrylic, polyuria
acrylic and urethane acrylic.
Further disclosed herein are processes for ing ink-jet printed fiber cement products, the
processes at least comprising the steps of:
- providing a fiber cement product suitable for being subjected to inkjet-printing, as described
herein, which fiber cement products at least comprise on at least part of their outer surface one
or more cured layers of a first g composition, which composition at least comprises a
binder and a t and is characterized by a pigment volume concentration (PVC) of higher
than about 40%,
- applying an ink print on top of the one or more cured layers of the first coating composition
by means of an -printer, and
- drying the ink print, so as to obtain an t printed fiber cement product.
In ular embodiments of the processes of the invention for producing ink-jet printed fiber
cement products, the ink print is formed by using an ink comprising at least one inorganic
pigment.
In further particular embodiments, the processes of the invention for producing ink-jet printed
fiber cement products, further comprise the steps of:
- applying one or more layers of a radiation-curable second coating composition on top of the
one or more cured layers of the first coating composition and/or on top of the dried ink print,
- radiation curing the one or more layers of the radiation-curable second coating composition.
Still further disclosed herein are ink-jet printed fiber cement products obtainable by the
processes as described above, which ink-jet printed fiber cement products at least comprise on
at least part of their outer surface:
- one or more cured layers of a first coating composition, at least comprising a binder and a
pigment, wherein the first coating composition is characterized by a pigment volume
concentration of higher than about 40%, and
- a dried ink print applied on top of the one or more cured layers of a first coating composition.
In ular embodiments, the ink print on the ink-jet printed fiber cement products of the
invention is formed by using a pigmented ink, which is t-based or which is water-based.
In particular embodiments, the ink print on the ink-jet printed fiber cement products of the
invention is formed by using an ink comprising at least one inorganic pigment.
In particular embodiments, the ink is not a ed ink.
In further ular ments, the ink-jet d fiber cement products of the invention
further comprise one or more radiation-cured layers of a second coating ition applied
on top of the one or more cured layers of the first g composition and/or on top of the
dried ink print.
Still further disclosed herein are uses of the fiber cement products suitable for being subjected
to ink-jet printing or uses of the ink-jet printed fiber cement ts as building materials. In
particular embodiments, the fiber cement products produced by the processes of the present
invention can be used to provide an outer surface to walls, both internal as well as external, a
building or construction, e.g. as façade plate, siding, etc.
The independent and dependent claims set out particular and preferred features of the
invention. Features from the dependent claims may be combined with features of the
4b followed by page 5
independent or other dependent claims, and/or with features set out in the description above
and/or after as appropriate.
The above and other characteristics, features and advantages of the present invention will become
apparent from the following detailed description, taken in conjunction with the accompanying
gs, which rate, by way of example, the principles of the ion. This description is
given for the sake of example only, without limiting the scope of the invention. The nce figures
quoted below refer to the attached drawings.
Brief description of the drawings
Figure 1 shows a schematic drawing of the composition of a coating composition comprising at least
a binder and at least a t with gradually increasing pigment volume concentrations.
Figure 2 shows a schematic drawing of a side view of a fiber cement t suitable for being
subjected to ink-jet printing according to an embodiment of the invention.
Figure 3 shows a schematic drawing of a side view of an ink—jet printed fiber cement product
according to an embodiment of the invention.
Figure 4 shows a schematic drawing of a top view of an ink—jet d fiber cement product
according to an embodiment of the invention.
The same reference signs refer to the same, similar or analogous elements in the ent figures.
1 Fiber cement product
2 Cured first coating composition
3 Binder
Voids
6 Ink pigment
7 Ink print
8 Radiation-cured second coating ition
Description of rative embodiments
The present invention will be described with respect to particular embodiments.
It is to be noted that the term ”comprising”, used in the claims, should not be interpreted as being
restricted to the means listed thereafter; it does not exclude other elements or steps. It is thus to be
interpreted as specifying the presence of the stated features, steps or components as referred to,
but does not preclude the presence or addition of one or more other features, steps or components,
or groups thereof. Thus, the scope of the expression ”a device comprising means A and B” should not
6 2016/054814
be limited to devices consisting only of components A and B. It means that with respect to the
present invention, the only relevant components of the device are A and B.
Throughout this specification, nce to ”one embodiment” or ”an embodiment” are made. Such
references te that a particular feature, described in relation to the embodiment is included in
at least one embodiment of the present invention. Thus, appearances of the phrases ”in one
embodiment” or “in an embodiment” in s places throughout this specification are not
necessarily all referring to the same embodiment, though they could. rmore, the particular
features or teristics may be combined in any suitable manner in one or more embodiments, as
would be apparent to one of ordinary skill in the art.
The following terms are provided solely to aid in the understanding of the invention.
As used herein, the singular forms ”a”, ”an”, and ”the” e both singular and plural referents
unless the context clearly dictates otherwise.
The terms ”comprising”, “comprises” and ”comprised of" as used herein are synonymous with
”including”, des” or ”containing”, ”contains”, and are inclusive or open-ended and do not
exclude additional, non-recited s, elements or method steps.
The recitation of numerical ranges by endpoints es all numbers and fractions subsumed within
the respective ranges, as well as the recited nts.
The term ” as used herein when referring to a measurable value such as a parameter, an
amount, a temporal duration, and the like, is meant to encompass variations of +/-10% or less,
preferably +/-5% or less, more preferably +/-1% or less, and still more ably +/-0.1% or less of
and from the specified value, insofar such variations are appropriate to perform in the disclosed
invention. It is to be understood that the value to which the modifier ”about” refers is itself also
specifically, and preferably, disclosed.
The terms ”(fiber) cementitious slurry” or “(fiber) cement slurry” as referred to herein generally refer
to slurries at least comprising water, fibers and cement. The fiber cement slurry as used in the
context of the present invention may also further comprise other components, such as but not
limited to, limestone, chalk, quick lime, slaked or hydrated lime, ground sand, silica sand flour, quartz
flour, amorphous silica, condensed silica fume, microsilica, metakaolin, wollastonite, mica, perlite,
vermiculite, aluminum hydroxide, pigments, anti-foaming agents, flocculants, and other additives.
”Fiber(s)” present in the fiber cement slurry as described herein may be for example process fibers
and/or reinforcing fibers which both may be organic fibers (typically ose fibers) or tic
fibers (polyvinylalcohol, polyacrilonitrile, opylene, polyamide, polyester, polycarbonate, etc.).
”Cement” present in the fiber cement slurry as described herein may be for example but is not
limited to Portland cement, cement with high alumina content, Portland cement of iron, trass-
cement, slag cement, r, calcium silicates formed by autoclave treatment and combinations of
particular binders. In more particular embodiments, cement in the ts of the invention is
Portland cement.
The term ”water—permeable” as used herein when referring to a water-permeable (region of a)
transport belt generally means that the material of which the water-permeable (region of the) belt is
made allows water to flow through its structure to a certain extent.
The ”water—permeability” as used herein when referring to the water-permeability of a (region of a)
ort belt generally refers to the extent or degree to which the material of which the water-
permeable (region of the) belt is made, allows water to flow through its ure. Suitable materials
for water—permeable transport belts are known to the person skilled in the art, such as but not
limited to felts.
The terms ”predetermined” and ”predefined” as used herein when referring to one or more
parameters or properties generally mean that the desired value(s) of these parameters or properties
have been determined or defined beforehand, i.e. prior to the start of the process for producing the
products that are characterized by one or more of these ters or properties.
A ”(fiber cement) sheet” as used herein, also referred to as a panel or a plate, is to be understood as
a flat, usually rectangular element, a fiber cement panel or fiber cement sheet being provided out of
fiber cement material. The panel or sheet has two main faces or surfaces, being the surfaces with the
largest surface area. The sheet can be used to provide an outer surface to walls, both internal as well
as al a ng or construction, e.g. as facade plate, siding, etc.
The term ”pigment volume concentration (abbreviated as PVC)” as used herein generally refers to
the amount of t(s) versus the total amount of solids (i.e. pigment(s), binder(s), other solids) in
a coating composition and can be calculated via the ing mathematical formula:
8 2016/054814
”Pigment volume concentration” (expressed in %) = ”PVC” (expressed in %) =
Volume of pigment/ (Volume of solids) * 100 (expressed in %) =
Volume of t/ (Volume of pigment + Volume of solid binder) * 100 (expressed in %) =
Volume of pigment/ e of pigment + Volume of non-volatile binder) * 100 (expressed in %)
The term ”Effective pigment volume concentration (abbreviated as effective PVC)” as used herein
lly refers to the amount of prime pigments (as defined herein) versus the total amount of
prime pigments and binder(s) in a coating composition and can be calculated via the following
mathematical formula:
”Effective pigment volume concentration” (expressed in %) = tive PVC” (expressed in %) =
(Volume of prime pigments)/ (Volume of prime pigments solid binder(s)) * + volume of 100
(expressed in %)
The term ”pigment” as used herein refers to a dry ble substance, usually pulverized, which
when suspended in a liquid vehicle s a paint, ink, etc. Pigments typically consist of tiny solid
particles that are used to enhance the appearance by providing color and/or to improve the physical
(functional) properties of the paint or ink. Pigments used to provide color generally range from 0.2 to
0.4 microns in diameter. Functional pigments are typically 2-4 microns in diameter, but they may be
as large as 50 microns.
The term ”prime pigment” as used herein refers to any pigment (as defined herein), which is capable
of providing whiteness and/or color to a substance while also contributing significantly to the hiding
power of said nce. Prime pigments can be subdivided in white pigments and color pigments.
The term ”white pigment” as referred to herein means a prime pigment, capable of ring light
and providing whiteness and hiding in flat or glossy paint or ink. White inorganic pigments include
but are not limited to antimony pigments including Antimony White: Sb203; lead pigments (toxic)
ing White Lead (PbC03)2-Pb(OH)2; titanium pigments including Titanium White: titanium(|V)
oxide TiOz and; zinc pigments including Zinc White: Zinc Oxide (ZnO).
The term ”color pigment” as referred to herein means a prime pigment, capable of selectively
absorbing light and providing color to a paint or ink. There are two main types of color pigments:
organic pigments, which include the er colors but are not highly durable in exterior use and
inorganic pigments, which are not as bright as organic colors but are the most durable exterior
pigments.
The term ”inorganic pigment” as used herein refers to naturally ing mineral coloring
compounds typically consisting of metallic salts. Inorganic pigments are usually oxides or sulphides of
one or more metals. Inorganic pigments include for instance but are not limited to:
-blue inorganic pigments:
oaluminum pigments, including ultramarine: a complex naturally occurring pigment of sulfur-
containing sodio-silicate (Nag_10AI6$i602452_4);
ocobalt pigments, including Cobalt Blue and Cerulean Blue:cobalt(ll) stannate;
ocopper pigments, including Egyptian Blue: a synthetic pigment of calcium copper silicate
(CaCuSi4010) and Han Blue BaCuSi4010; and
oiron pigments, including Prussian Blue: a synthetic pigment of ferric hexacyanoferrate (Fe7(CN)18);
-green inorganic pigments
ocadmium pigments, including EBM.|nfra.Shared.Etex wiki Cadmium i ments Viridian: a dark
green pigment of hydrated um(|||) oxide (Cr203) and Cadmium Green: a light green pigment
consisting of a e of m Yellow (CrS) and Viridian (Cr203);
ochromium pigments, including Chrome Green;
r pigments, including Paris Green: copper(|l) acetoarsenite (Cu(C2H302)2-3Cu(AsOZ)2) and
Scheele‘s Green (also called s Green): copper arsenite CUHASOg;
-yellow inorganic pigments
oarsenic pigments including Orpiment l monoclinic arsenic sulfide (A5253);
ocadmium pigments including Cadmium Yellow:cadmium sulfide (CdS);
ochromium pigments including Chrome Yellow: natural pigment of |ead(||) chromate (PbCrO4);
ocobalt pigments including in (also called Cobalt ): Potassium cobaltinitrite
lNozle;
oiron pigments including Yellow Ochre: a naturally occurring clay of hydrated iron oxide (Fe203.H20);
olead pigments including Naples ;
otitanium pigments including Titanium Yellow;
otin pigments including Mosaic gold: stannic sulfide (SnSz);
-orange inorganic pigments
um ts including Cadmium Orange: an intermediate between m red and
cadmium yellow: cadmium elenide;
ochromium pigments including Chrome Orange: a lly occurring pigment mixture composed of
lead(||) chromate and lead(l|) oxide. (PbCrO4 + PbO)
-red nic pigments
ocadmium pigments ing Cadmium Red: cadmium selenide (CdSe);
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oiron oxide ts including Sanguine, Caput Mortuum, Oxide Red, Red Ochre: anhydrous Fe203,
Burnt Sienna: a pigment produced by heating Raw , Venetian Red;
olead ts ) including Red Lead: lead tetroxide, Pb304,
omercury pigments (toxic) including Vermilion: Synthetic and natural pigment: Occurs naturally in
mineral cinnabar; Mercuric sulfide (HgS);
-brown inorganic pigments
oclay earth pigments (naturally formed iron oxides) including Raw Umber: A natural clay pigment
ting of iron oxide, manganese oxide and aluminum oxide: Fe203 + MnOz + nHZO + Si + NO;
Raw Sienna: a lly occurring yellow-brown pigment from limonite clay;
-b|ack inorganic pigments
n pigments including Carbon Black, Ivory Black, Vine Black, Lamp Black;
olron Pigments including Fe304;
oTitanium pigments: Titanium Black;
-grey inorganic ts
oPayne's grey: a mixture of Ultramarine and black or of Ultramarine and Sienna;
The term ”organic pigment” as used herein refers to synthetic organic coloring compounds, which
are carbon based molecules manufactured from petroleum compounds, acids, and other chemicals,
usually under intense heat or pressure.
Organic pigments include for instance but are not limited to:
w organic pigments:
Yellow Lakes, which are transparent pigments used as a yellow to cover other inks but not hide them,
zine Yellow Lake (also called FD&C Yellow No. 5 and used as a dyestuff in foods), Hansa
Yellows, and Diarylide Yellows, which are the most common yellow pigments used in printing inks.
Fluorescent Yellow is also used in some specialty applications. Organic Yellows are commonly used to
replace Chrome s;
-orange organic pigments:
The most common orange pigment is Diarylide Orange, a transparent yet not very fast-to-light
pigment. Other assorted orange materials tend to be used where orange pigments are necessary,
and include DNA Orange, Pyrazolone Orange, Fast Orange F26, Benzimidazolone Orange HL, and
Ethyl Lake Red C;
-red organic pigments:
Reds include Para Reds, ine Red, [“Permanent Red "R"], Carmine F.B., Naphthol Reds and
Rubines, ent Red FRC, Bordeaux FRR, Rubine Reds, Lithol Reds, BON Red, Lithol Rubine 4B,
BON Maroon, Rhodamine 66, Lake Red C, BON Arylamide Red, Quinacrinone Magentas, Copper
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Ferrocyanide Pink, Benzimidazolone Carmines and Reds, Azo Magenta G, Anthraquinone Scarlet, and
Madder Lakes;
-b|ue c pigments:
'Blues'. Blues include Phthalocyanine Blues (the most commonly used group of organic blue
pigments), PMTA Victoria Blue, Victoria Blue CFA, Ultramarine Blue, lndanthrene Blue, Alkali Blues,
and Peacock Blue;
-violet organic pigments:
Violets overlap slightly with some of the bluer reds (such as Benzimidazolone Bordeaux HF 3R (see
Benzimidazolone Carmines and Reds), and also include such pigments 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 series of greens are the Phthalocyanine Greens as well as the PMTA Greens;
-brown organic pigments:
Brown pigments include Diazo Brown and Benzimidazolone Brown HFR;
The terms der pigment” or r pigment” as used herein refers to any pigment (as d
) having a low refractive index or opacity and therefore not ing color or hiding power to
a substance. Extender or filler pigments appear transparent in a paint or ink. Extender pigments have
significant positive effects on various properties of the paint for example, as described further below,
mica can improve the water ance of a film due to its "platy" particle shape and tendency to
orient itself in overlapping layers horizontal to the surface. Extender pigments or filler pigments for
ce include but are not limited to Barium te, Calcium Carbonate, Magnesium Silicate
Mica, Kaolin (China Clay), ine, Talc, Silica / Quartz, Alumina Hydrate, Kalunite, Pumice,
Bentonite, Vermiculite, and Glass Beads.
The term ”UV-curable” or ”UV-cured” refers to a composition that can polymerize upon application
of UV irradiation. Typically, this at least implies the presence of photo-polymerizable monomers or
oligomers, together with photoinitiators and/or photosensitizers.
The term ”solvent-based ink” as used herein refers to an ink comprising pigments in a colloidal
suspension in a solvent other than water. The main t in solvent-based inks is typically one or
more volatile organic compounds, such as but not limited to l, ethyl acetate, ne glycol,
glycol esters, hexane, isopropanol, nol, methyl ethyl ketone, mineral spirits, naphthas,
normal propyl acetate, normal propyl alcohol, toluene and xylene.
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The term ”water-based ink” as used herein refers to an ink comprising ts in a dal
suspension in water. All though the main solvent in water-based inks is water, there can also be
other co-solvents present. These co-solvents typically are volatile organic compounds, such as but
not limited to ethanol, ethyl acetate, ethylene glycol, glycol esters, hexane, panol, nmethanol,
methyl ethyl ketone, mineral spirits, naphthas, normal propyl acetate, normal propyl alcohol, toluene
and xylene.
The terms ”UV-cured ink” or ”UV-curable ink” as interchangeably used herein refer to an ink
composition that can polymerize upon application of UV irradiation. A ”UV-cured ink” or "UV-curable
ink” as used herein refers to an ink composition which does not comprise a solvent but rather
comprises one or more pigments embedded in a matrix of photo-polymerizable monomers and/or
oligomers, and photoinitiators and/or photosensitizers.
The invention will now be further explained in detail with nce to various embodiments. It will
be tood that each embodiment is ed by way of example and is in no way limiting to the
scope of the invention. In this respect, it will be clear to those skilled in the art that various
cations and variations can be made to the present invention without departing from the scope
or spirit of the invention. For instance, es illustrated or described as part of one embodiment,
can be used in another embodiment to yield a still further embodiment. Thus, it is intended that the
present invention covers such modifications and variations as encompassed within the scope of the
appended claims and equivalents f.
The present invention provides fiber cement products having ed properties with regard to the
capability of being subjected to ink—jet printing processes. In particular, up to now, the m has
always existed that printing, and in particular ink-jet printing with solvent-based or water-based inks,
was very difficult, if not impossible, to achieve on fiber cement surfaces per se. This is unlike other
materials, such as ceramics or glass, which are easily provided with informative or decorative
patterns by ink-jet printing. The main reason for this difference is that fiber cement compositions
have the inherent structural properties of a high degree of heterogeneity and surface ess,
inevitably causing issues of ink bleeding, a phenomenon that is terized by jagged print edges
and even undesirable ink stains around or adjacent to the printed patterns or prints.
In order to solve these problems, the present inventors have developed novel and improved fiber
cement products that can be ink-jet printed with ional solvent-based or water-based pigmented
inks with high efficiency and performance.
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In particular, it was found that by coating fiber cement products with a coating composition, wherein
the amount of pigments versus the total amount of solids (e.g. pigments and solid binder
ents) in the coating composition (i.e. the so-called ”pigment volume concentration” (PVC) of
the coating composition) is higher than about 40%, ink-jet printing can be performed without
encountering any of the above—stated issues.
The inventors believe that this observed beneficial effect is due to the fact that the porosity of a
coating layer having a PVC of at least about 40% is higher than the porosity of outer surfaces of
known coated fiber cement products. This sed porosity results in the fact that the coating layer
applied to the fiber cement products is able to absorb and capture the ink ition relatively
quickly after ink-jetting, thereby preventing this ink composition from being able to spread out over
the surface of the coated fiber cement product.
ingly, the fiber cement products according to the present invention are characterized by
sing a pigmented coating layer with a PVC of at least about 40%, thereby achieving the effect
of obtaining both a uniform surface and a homogenous and high porosity. This effect has the
advantage that, when these products are ted to ink—jet printing with a solvent-based or with a
water-based ink, a homogeneous and equal print quality all over the surface of the fiber cement
product is obtained.
Thus, in a first aspect, the present ion provides fiber cement products suitable for being
ted to inkjet—printing, which fiber cement products at least se on at least part of their
outer surface one or more cured layers of a first g composition, which composition at least
comprises a binder and a pigment and is characterized by a pigment volume concentration (PVC; as
defined herein) of higher than about 40%.
In the context of the present invention, fiber cement products are to be tood as cementitious
products comprising cement and synthetic (and optionally natural) fibers. The fiber cement products
are made out of fiber cement slurry, which is formed in a so-called ”green” fiber cement product,
and then cured.
Dependent to some extent on the curing process used the fiber cement slurry lly comprises
water, process or rcing fibers which are synthetic organic fibers (and optionally also natural
organic fibers, such as cellulose), cement (e.g. Portland cement), limestone, chalk, quick lime, slaked
or ed lime, ground sand, silica sand flour, quartz flour, amorphous silica, condensed silica
fume, microsilica, kaolin, metakaolin, wollastonite, mica, perlite, vermiculite, aluminum hydroxide
(ATH), pigments, anti-foaming agents, flocculants, and/or other additives. Optionally color additives
(e.g. pigments) are added, to obtain a fiber cement t which is so-called colored in the mass.
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In particular embodiments, the fiber cement products of the invention have a thickness of n
about 4 mm and about 200 mm, in particular between about 6 mm and about 200 mm, more in
particular between about 8 mm and about 200 mm, most in particular between about 10 mm and
about 200 mm.
The fiber cement products as referred to herein include roof or wall covering products made out of
fiber cement, such as fiber cement s, fiber cement boards, flat fiber cement sheets, corrugated
fiber cement sheets and the like. According to particular embodiments, the fiber cement products
according to the invention can be roofing or facade elements, flat sheets or corrugated sheets.
According to further particular embodiments, the fiber cement ts of the present invention are
fiber cement sheets.
The fiber cement products of the present invention comprise from about 0.1 to about 5 weight%,
such as particularly from about 0.5 to about 4 weight% of fibers, such as more particularly between
about 1 to 3 weight% of fibers with respect to the total weight of the fiber cement product.
According to particular ments, the fiber cement products according to the invention are
characterized in that it comprises fibers chosen from the group consisting of cellulose fibers or other
inorganic or organic reinforcing fibers in a weight % of about 0.1 to about 5. In particular
embodiments, organic fibers are selected from the group consisting of polypropylene,
polyvinylalcohol polyacrylonitrile fibers, polyethyelene, cellulose fibres (such as wood or annual kraft
pulps), polyamide fibers, polyester fibers, aramide fibers and carbon fibers. In r particular
ments, inorganic fibers are selected from the group consisting of glass fibers, rockwool fibers,
slag wool fibers, wollastonite fibers, ceramic fibers and the like. In further particular embodiments,
the fiber cement products of the present invention may se fibrils s, such as for example
but not d to, polyolefinic fibrils fibrids % in a weight % of about 0.1 to 3, such as ”synthetic
wood pulp”.
According to certain particular embodiments, the fiber cement products of the present invention
comprise 20 to 95 weight % cement as hydraulic binder.
Cement in the products of the invention is selected from the group consisting of Portland ,
cement with high alumina t, Portland cement of iron, trass-cement, slag cement, plaster,
calcium silicates formed by autoclave treatment and combinations of particular s. In more
ular embodiments, cement in the products of the invention is Portland cement.
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According to particular embodiments, the fiber cement products according to the invention
optionally comprise further components. These further components in the fiber cement products of
the present invention may be selected from the group consisting of water, sand, silica sand flour,
condensed silica fume, ilica, fly-ashes, amorphous silica, ground quartz, the ground rock, clays,
pigments, kaolin, metakaolin, blast furnace slag, carbonates, puzzolanas, aluminium hydroxide,
wollastonite, mica, perlite, calcium carbonate, and other additives (e.g. colouring additives) etc. It
will be understood that each of these components is present in suitable amounts, which depend on
the type of the specific fiber cement product and can be determined by the person skilled in the art.
In particular embodiments, the total quantity of such r components is preferably lower than 70
weight % ed to the total initial dry weight of the composition.
Further additives that may be present in the fiber cement products of the present invention may be
selected from the group consisting of dispersants, plasticizers, antifoam agents and flocculants. The
total quantity of additives is preferably between about 0.1 and about 1 weight % compared to the
total l dry weight of the composition.
The first coating composition ed on the surface of the fiber cement products of the invention
at least comprises a binder and a t.
Binders and pigments for coating compositions are known in the art and are not critical to the
invention as long as the coatings are terized by a pigment volume tration (PVC; as
defined herein) of higher than about 40%. In particular embodiments, the first g layer provided
on the surface of the fiber cement products of the invention is not curable by radiation or by
chemical crosslinking.
Suitable binder compositions for use as a first coating layer in the products of the t invention
are for example binders obtained by aqueous free radical or ionic emulsion polymerization. For
ce, suitable binders for use as a first coating layer in the products of the present ion are
acrylic and/or methacrylic (co-) polymers. Such c and/or rylic olymers are usually
prepared by aqueous radically ted emulsion polymerization of esters of acrylic acid and/or
methacrylic acid with C1-C12 alkanols as well as a minor amount of acrylic and/or methacrylic acid as
monomers. In this regard, preference is given in particular to esters of acrylic and methacrylic acid
with C1-C8 alkanols.
Thus, in particular embodiments, the binding polymer may be provided as a pure acrylic, a styrene
acrylic, a fluoropolymer acrylic, a urethane acrylic, a vinyl acrylic and/or an acrylated ethylene vinyl
acetate copolymer or combinations thereof. The polymer may be derived from at least one acrylic
wo 2016/146423 16
monomer, such as an acrylic acid, c acid ester, methacrylic acid, and methacrylic acid ester.
Typically, the binding polymer is derived from one or more monomers, examples of which include
polyvinylidine fluoride, styrene, methyl styrene, vinyl chloride, acrylonitrile, methacrylonitrile,
ureido methacrylate, vinyl acetate, vinyl esters of branched tertiary monocarboxylic acids, itaconic
acid, crotonic acid, maleic acid, fumaric acid, ethylene, and C4—C8 conjugated dienes.
In certain particular embodiments, the g polymer of the first coating composition of the
products of the invention is selected for degree of hydrophobicity and/or particle size. Polymeric
particles for compositions described herein are typically in the nanometer size range, while
polymeric particles in other tional paint formulations range in size from 50 to 250
ters.
The binder of polymeric particles is typically provided at a weight percent (wt%) of less than 60%,
preferably at a range at or about 20-55% for a water-based first g provided herein.
The first coating composition provided on the surface of the fiber cement products of the invention
further comprises one or more pigments so as to obtain a t volume concentration (PVC, as
defined herein) of at least 40%. Pigments provide color, hiding, and/or are t as ers.
Pigments include those in the form of titanium oxide, iron oxides, m carbonate, spinell
pigments, titanates, clay, aluminum oxide, silicon dioxide, magnesium oxide, magnesium silicate,
barium metaborate monohydrate, sodium oxide, potassium oxide, talc, barytes, zinc oxide, zinc
e and mixtures thereof or organic alkaliresistant pigments such as phtalocyanines and azo
compounds.
In particular embodiments, the first coating composition ing to the invention comprises one or
more prime pigments (as defined herein) such that an effective pigment volume concentration
(effective PVC, as defined herein) of at least 40% is achieved. As defined herein, the volume
percentage of pigments other than prime pigments, such as but not limited to the volume of
extender pigments or filler pigments (as defined herein), is not ed in the calculation of the
effective pigment volume concentration. The effective PVC of the first coating composition is
therefore calculated only by taking into consideration the volume of prime ts versus the total
volume of prime pigment(s) and solid binder(s) in the ition. The inventors have found that
when prime pigments are present in the first coating composition in an effective pigment volume
concentration of at least 40%, extremely good ng results are achieved.|n particular
embodiments, the one or more prime pigments included in the first coating composition ed on
the surface of the fiber cement products of the invention are one or more white colored pigments,
wo 2016/146423 17
such as but not d to antimony pigments, barium pigments, lead pigments, titanium pigments,
and zinc pigments. In further particular embodiments, the one or more prime pigments included in
the first coating layer ed on the surface of the fiber cement products of the invention are one
or more white colored pigments, such as but not limited to stibous oxide (Antimony White, Sb203),
basic plumbous carbonate (PWl, Cremnitz White, (PbC03)2-Pb(OH)2), c oxide (PW6, Titanium
White, TiOz), and zinc oxide (PW4, Zinc White, ZnO).
In r particular embodiments, the prime pigments suitable for use in the first coating
ition in the processes and products of the present invention so as to obtain an effective PVC
of at least 40% are one or more white prime pigments. In yet further ular embodiments, the
prime pigments suitable for use in the first coating composition in the processes and products of the
present invention at least comprise titanium dioxide (TiOZ).
In particular embodiments of the present invention, the pigments suitable for use in the first coating
composition in the processes and products of the present invention are essentially alkali-resistant,
i.e. resistant to a pH of about 8 or higher, such as resistant to a pH of about 9 or higher, such as
resistant to a pH of about 10 or , such as resistant to a pH of about 11 or higher, more
particularly resistant to a pH of higher than about 12 or higher than about 13.
The coating composition used for ing the first coating layer on the surface of the fiber cement
products of the invention r comprises, besides the polymeric binders and pigments, also usual
auxiliaries, e.g. s, cing agents, anti-blistering agents, rheology modifiers, surfactants,
g agents, viscosity modifiers, dispersants, defoamers, preservatives and hydrophobisizers,
biocides, fibers, colorants, waxes, perfumes and co-solvents and other usual constituents. Examples
of suitable fillers are aluminosilicates, silicates, alkaline-earth metal carbonates, preferably calcium
carbonate in the form of calcite or lime, dolomite, and also aluminum silicates or magnesium
silicates, e.g. talc.
Accordingly, the coating composition used for providing the first coating layer on the surface of the
fiber cement products of the invention further may comprise one or more film-forming aids or
coalescing agents. Suitable firm-forming aids or coalescing agents e glycol ethers (e.g.,
ts from Eastman Chemical Company, Kingsport, Tenn., including DB, EB, PM, EP) and ester
alcohols (e.g., ts from Eastman Chemical Company, Kingsport, Tenn., ing Texanol), as
examples.
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In addition to the above, the coating composition used for providing the first coating layer on the
surface of the fiber cement products of the invention further may comprise one or more additives
included for properties, such as regulating flow and leveling, sheen, foaming, yellowing, ance to
stains, cleaner, burnish, block, mildew, dirt, or corrosion, and for retaining color and gloss.
The emulsion rization of the coating composition es the use of surfactants as stabilizers.
Non-ionic 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.
Examples of suitable surface-active dispersing or wetting agents include those available under the
trade designations, such as STRODEX"VI KK-95H, STRODEX“VI PLFlOO, XTM PKOVOC, XT'VI
LFK LFK70, STRODEXTM SEK50D, and DEXTROL® OC50 (trademarks of Dexter Chemical LLC,
Wilmington, Del.); HYDROPALA TM 100, HYDROPALATTM 140, HYDROPALAT1M 44, HYDROPALATTM 5040
and ALATTM 3204 marks of Cognis Corp., Monheim, Germany); LIPOLINTM A, DISPERSTM
660C, DISPERSTM 715W (trademarks of Evonik a GmbH, Germany); BYK® 156, BYK® 2001 and
ERRA"VI 207 marks of Byk-Cera, Germany); DISPEXTM A40, DISPEXTM N40, DISPEXTM R50,
DISPEXTM G40, DISPEXTM GA40, EFKA® 1500, EFKA® 1501, EFKA® 1502, EFKA® 1503, EPKATM 3034,
EFKA® 3522, EFKA® 3580, EFKATM 3772, EFKA® 4500, EFKA® 4510, EFKA® 4520, EFKA® 4530, EFKA®
4540, EFKA® 4550, EFKA® 4560, EFKA® 4570, EFKA® 6220, EFKA® 6225, EFKA® 6230 and EFKA® 6525
(trademarks of Ciba Specialty Chemicals, Basil, Switzerland); SURFYNOLTM CT-111, SURFYNOLTM CT-
121, SURFYNOLTM CT-131, SURFYNOLTM CT-211, SURFYNOL‘” CT 231, SURFYNOLTM CT-136,
SURFYNOLTM , SURFYNOLTM CT-171, SURFYNOLTM CT—234, CARBOWETTM DC-01, SYRFYNOLTM 104,
OLTM PSA-336, SURFYNOL‘”I 420, OLTM 440, ENVIROGEMTM AD-Ol and ENVIROGEMTM
AE01 (trademarks of Air Products and Chemicals, Inc, Lehigh Valley, Pa.); TAMOLTM 1124, TAMOLTM
165A, TAMOTM 850, TAMOLTM 681, TAMOLTM 731 and TAMOLTM SG—1 (trademarks of Rohm & Haas
Company, Philadelphia, Pa.); IGEPALTM CO-210, IGEPALTM CO-430, TM CO-630, IGEPALTM CO-730,
and |GEPALTM CO-890 (trademarks of Rhodia |nc., Cranbury, N.J.); T—DETW‘ and T-MULZTM (trademarks
of Harcros Chemicals Inc., Kansas City, Kans.).
es of suitable defoamers include but are not limited to BYKT'V' 018, BYK® 019, BYK® 020, BYK®
022, BYK® 025, BYK® 032, BYK® 033, BYK® 034, BYK® 038, BYK® 040, BYK® 060, BYK® 070 and BYK®
077 (trademarks of Byk-Cera, Germany); SURFYNOLTM DF—695, SURFYNOLTM DF-75, SURFYNOLTM DF—
62, SURFYNOLTM DF-40 and SURPYNOLTM DF-110D (trademarks of Air Products and Chemicals, Inc.,
Lehigh Valley, Pa.); DEE FO® 3010A, DEE FO® 2020E/50, DEE FO® 215, DEE FO® 806-102 and
wo 2016/146423 19
AGITANTM 3lBP, AGITANTM 731 (trademarks of Munzing Chemie GmbH, Germany); EFKA® 2526,
EFKA® 2527 and EFKA® 2550 (trademarks of Ciba Specialty Chemicals, Basil, Switzerland); TEGO®
Foamex 8050, TEGO® Foamex 1488, TEGO® Foamex 7447, TEGO® Foamex 800, TEGO® Foamex 1495
and TEGO® Foamex 810 (trademarks of Evonik Degussa GmbH, Germany); FOAMASTER® 714,
FOAMASTER® A410, TER® 111, FOAMASTER® 333, FOAMASTER® 306, FOAMASTER® SA-3,
FOAMASTER® AP, DEHYDRAN® 1620, DEHYDRAN® 1923 and DEHYDRAN® 671 (trademarks of Cognis
Corp., Monheim, Germany).
A thickener and rheology modifier is included for ing spreading, handling, and application of
the coating composition, when desired. Preferably, the thickener is a non-cellulosic ner clue to
preferred non moisture swelling characteristics. Associative thickeners such as, for example,
hydrophobically modified alkali swellable acrylic copolymers and hobically modified urethane
copolymers generally impart more Newtonian rheology to emulsion paints compared to conventional
thickeners such as, for example, osic thickeners. Cellulosic thickeners perform by swelling in
water and are undesirable in several preferred embodiments as further described herein.
entative examples of suitable associative thickeners used herein include AcrysolTM RM SW and
AcrysolTM RM-2020 NPR (trademarks of Rohm & Haas y, Philadelphia, Pa.).
Coating compositions used for providing the first coating layer on the surface of the fiber cement
products of the invention further may also comprise other additives, such as plasticizer, anti-foam
agent, pH adjuster (amine or ammonia), g color, and biocide. Such g additives are
typically present in the formulation in an amount from about 0 to about 18% by weight or up to 18
by weight and from about 1 to about 15% by weight based on the total weight of the formulation.
In addition, coating itions used for providing the first g layer on the surface of the fiber
cement products of the invention may include one or more functional extenders to increase
ge, reduce cost, achieve durability, alter appearance, control rheology, and/or influence other
desirable properties. Examples of functional extenders include, for example, barium sulphate,
aluminum silicate, magnesium silicate, barium sulphate, calcium carbonate, clay, gypsum, silica, and
talc.
In several ments, it will be ble to e a biocide or mildewicide, or fungicide to the
coating compositions used for providing the first coating layer on the surface of the fiber cement
products of the ion. Preferred examples include but are not limited to barium sulphate,
ROZONETM 2000, BUSANTM 1292, BUSAN 11M1, BUSAN 11M2, and BUSAN 1440 (trademarks of Rohm
& Haas Company, elphia, Pa., or its subsidiaries or affiliates); POLYPHASE® 663 and
wo 46423 20
POLYPHASE® 678 (trademark of Troy Chemical Corporation, Newark, NJ); and KATHONT'" LX
(trademark of Rohm & Haas y, Philadelphia, Pa., or its subsidiaries or affiliates.)
Coating compositions used for providing the first coating layer on the surface of the fiber cement
products of the invention are typically ated to include at least about 50% by volume of dry
solids. In particular embodiments, the balance of the coating compositions used for providing the
first coating layer on the surface of the fiber cement products of the invention is water. Water is
present with the binding polymer when provided in a dispersion and in other components of the
coating itions. Water is generally also added separately.
In ular embodiments, the first coating composition of the fiber cement products suitable for
being ted to inkjet-printing is characterized by a pigment volume concentration (PVC, as
defined ) of at least about 40%, particularly between about 40% and about 80%, such as
n about 40% and about 70%, more particularly between about 40% and 60%. In further
particular embodiments, the first coating composition of the fiber cement products suitable for being
subjected to inkjet-printing is characterized by a pigment volume concentration of at least about
50%, more ularly between about 50% and about 80%, such as between about 50% and about
70%, most ularly between about 50% and about 60%. In yet further particular embodiments,
the first coating composition of the fiber cement products suitable for being subjected to inkjet-
printing is characterized by a pigment volume concentration of between about 40% and about 50%,
more particularly between about 45% and about 50%, such about 46%. In further particular
embodiments, the cured first coating layer of the fiber cement products suitable for being ted
to inkjet-printing is characterized by a pigment volume concentration (PVC) of at least about 40%,
such as at least about 45%, in particular at least about 50%, such as at least about 55%, more
particularly at least about 60%, such as at least about 65%, most particularly at least about 70%, such
as at least about 75%, or at least about 80%.
In yet further particular embodiments, the first coating composition of the fiber cement products
suitable for being subjected to inkjet-printing is characterized by an effective pigment volume
tration (effective PVC, as defined herein) of at least about 40%, particularly between about
40% and about 80%, such as between about 40% and about 70%, more particularly between about
40% and 60%. In further particular embodiments, the first coating ition of the fiber cement
products suitable for being subjected to inkjet-printing is characterized by an effective pigment
volume concentration of at least about 50%, more particularly between about 50% and about 80%,
such as between about 50% and about 70%, most particularly n about 50% and about 60%. In
yet further ular embodiments, the first coating composition of the fiber cement products
wo 2016/146423 21
le for being subjected to inkjet-printing is characterized by an effective pigment volume
concentration of between about 40% and about 50%, more particularly between about 45% and
about 50%, such about 46%. In further particular embodiments, the cured first coating layer of the
fiber cement products le for being subjected to inkjet-printing is characterized by an effective
pigment volume concentration (PVC) of at least about 40%, such as at least about 45%, in particular
at least about 50%, such as at least about 55%, more particularly at least about 60%, such as at least
about 65%, most particularly at least about 70%, such as at least about 75%, or at least about 80%.
In particular embodiments, the minimum film forming temperature during the drying of the one or
more layers of the first coating composition of the fiber cement products suitable for being subjected
to -printing is below about 60°C.
In further particular embodiments, the first coating composition used for providing the one or more
first coating layers on the surface of the fiber cement products of the invention ses as liquid
component essentially water and, if desired, an organic liquid miscible with water, for example an
alcohol. The first coating composition is applied as a wet coating weight in the range from about 30
to about 500 g/m2, in particular from about 40 to about 300 g/m2, more in particular from about 50
to about 500 g/m2, in a known manner, for example by ng, trowelling, knife application,
brushing, rolling, curtain coating or pouring onto the cement bonded board, or by a combination of
one or more applications. In particular embodiments, the first coating composition is preferably
applied by spraying.
Thus the coating compositions described herein can be applied to a surface of a fiber cement product
using a brush, blade, roller, sprayer (e.g., sisted or airless, electrostatic), vacuum coater,
curtain coater, flood coater or any suitable device that promotes an even distribution of the coating
composition over the surface, even if the e is damaged, worn, or cracked. The coating
itions may be applied to provide a smooth surface, colored surface or textured e. A
portion or an entire surface of the fiber cement product may be coated at one time. In on or as
an alternative, all or a portion of the surface may be coated more than one time to achieve the
desired thickness, gloss, and/or surface effect. The amount of coverage obtained by a quantity of the
composition will vary depending on the desire and/or condition of the surface to be d and the
ess of the coating applied.
In a second aspect, the present ion es processes for producing a fiber cement product
suitable for being subjected to ink—jet printing.
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A first step in these methods of the invention is providing a fiber cement product, which can be
performed according to any method known in the art for ing fiber cement products,
essentially consisting of at least water, cement and fibers.
In this step, a fiber cement slurry can first be prepared by one or more sources of at least cement,
water and fibers. In certain specific embodiments, these one or more sources of at least cement,
water and fibers are operatively connected to a continuous mixing device ucted so as to form a
itious fiber cement slurry. In particular embodiments, when using cellulose fibers or the
equivalent of waste paper fibers, a m of about 3%, such as about 4%, of the total slurry mass
of these cellulose fibers is used. In further particular embodiments, when exclusively cellulose fibers
are used, between about 4% to about 12%, such as more particularly, between about 7% and about
%, of the total slurry mass of these cellulose fibers is used. If cellulose fibers are replaced by short
mineral fibers such as rock wool, it is most ageous to replace them in a proportion of 1.5 to 3
times the weight, in order to maintain approximately the same content per volume. In long and cut
fibers, such as glass fiber s or synthetic high-module fibers, such as polypropylene, polyvinyl
acetate, polycarbonate or acrylonitrile fibers the proportion can be lower than the proportion of the
replaced ose fibers. The fineness of the fibers (measured in Shopper-Riegler degrees) is in
principle not critical to the processes of the invention. Yet in particular embodiments, it has been
found that a range between about 15 DEG SR and about 45 DEG SR can be particularly advantageous
for the processes of the invention.
Once a fiber cement slurry is ed, the manufacture of the reinforced cement products can
be executed according to any known procedure. The process most widely used for cturing
fiber cement products is the Hatschek process, which is performed using a modified sieve cylinder
paper making machine. Other manufacturing processes include the Magnani s, injection,
extrusion, flow-on and others. In ular embodiments, the fiber cement products of the present
invention are provided by using the ek process. The ”green” or uncured fiber cement product
is optionally post-compressed usually at pressures in the range from about 22 to about 30 MPa to
obtain the desired density.
The processes according to the present ion may further comprise 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 but not
limited to water jet cutting, air jet cutting or the like. The fiber cement products can be cut to any
desirable length, such as but not limited to a length of between about 1 m and about 15 m, such as
wo 2016/146423 23
between about 1 m and about 10 m, more particularly between about 1 m and about 5 m, most
particularly between about 1 m and about 3 m.
It will be understood by the skilled person that the processes of the present invention may further
comprise additional steps of processing the ed fiber cement products.
For instance, in certain particular embodiments, during the processes of the present invention, the fiber
cement slurry and/or the fiber cement products may undergo various intermediate treatments, such as
but not limited to treatment with one or more hobic agents, treatment with one or more
flocculants, additional or intermediate pressing steps, etc.
As soon as the fiber cement products are formed, these are trimmed at the lateral edges. The border strips
can optionally be recycled through immediate mixing with the ed water and directing the mixture to
the mixing system again.
In particular embodiments, the ed fiber cement products are cured. Indeed, after production,
fiber cement products can be allowed to cure over a time in the environment in which they are
formed, or alternatively can be subjected to a thermal cure (e.g. by autoclaving or the like).
In further particular ments, the ”green” fiber cement product is cured, lly by curing to
the air (air cured fiber cement products) or under pressure in presence of steam and increased
temperature lave cured). For autoclave cured products, typically sand is added to the original
fiber cement slurry. The autoclave curing in principle results in the ce of 11.3 A (angstrom)
Tobermorite in the fiber cement product.
In yet r particular embodiments, the ”green” fiber cement product may be first pre-cured to
the air, after which the pre-cured product is further air-cured until it has its final strength, or
autoclave-cured using pressure and steam, to give the product its final properties.
In particular embodiments of the present invention, the processes may further comprise the step of
lly drying the obtained fiber cement products. After curing, the fiber cement product being a
panel, sheet or plate, may still comprise a significant weight of water, present as humidity. This may
be up to 10 even 15 %w, expressed per weight of the dry t. The weight of dry t is
d as the weight of the product when the product is subjected to drying at 105°C in a ventilated
furnace, until a constant weight is obtained.
In certain embodiments, the fiber cement product is dried. Such drying is done preferably by air
drying and is terminated when the weight percentage of humidity of the fiber cement product is less
wo 2016/146423 24
than or equal to 8 weight %, even less than or equal to 6 weight %, expressed per weight of dry
product, and most ably between 4 weight % and 6 weight %, inclusive.
The next step in the methods of the invention for producing fiber cement products le for being
subject to ink-jet printing comprises applying to at least part of the outer surface of the fiber cement
product, one or more layers of a first g composition, which composition at least ses a
binder and a t and is characterized by a t volume concentration of higher than about
40%. Further characteristics of the first coating composition are as defined and described above for
the products according to the invention.
A further step in the methods of the invention for producing fiber cement products suitable for being
t to ink-jet printing comprises curing the one or more layers of the first coating composition so
as to obtain a fiber cement product suitable for being subjected to inkjet-printing. In principle, any
suitable curing step known in the art can be d for film-forming, drying and hardening the one
or more layers of the first coating composition. In particular embodiments, the first coating
composition is dried at room temperature or preferably at elevated temperature, for example from
40 to 150 °C. The dry thickness of the first conventional coating is generally from about 20 Pm to
about 100 Pm, preferably from about 50 Pm to about 70 Pm.
In a third aspect, the present invention provides processes for producing an ink-jet printed fiber
cement product.
A first step in these processes comprises providing a fiber cement t according to the
invention, which is le for being subjected to ink—jet printing as described herein, which product
comprises on at least part of its outer surface one or more cured layers of a first coating composition
at least comprising a binder and a pigment, wherein the first coating composition is characterized by
a pigment volume concentration of higher than about 40%.
Before the ink print is applied, the first coating composition is dried at room ature or
preferably at elevated temperature, for example from about 40°C to about 150°C. The dry thickness
of the first coating composition is generally from about 20 um to about 100 um, preferably from
about 50 um to 70 pm.
A next step in the processes for ing an ink—jet printed fiber cement product ing to the
invention comprises applying an ink print on top of the one or more cured layers of the first coating
composition by means of an inkjet-printer.
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The step of applying an ink print on the one or more cured layers of a first coating composition of the
fiber cement ts according to the invention can be done by any known ink—jet based process
using an ink, at least comprising: a liquid vehicle and one or more pigments.
Thus, in particular embodiments of the invention, the ink is not a UV-cured ink or a UV-curable ink
(as defined herein), since these inks do not comprise a liquid vehicle.
The ink is characterized by several features. It has a viscosity which enables it to be printed by ink-jet
printing, typically a viscosity (at room temperature) of below about 50 cps, or a viscosity at jetting
temperature (the temperature present at the ink printhead during printing) of below about 20 cps,
most preferably below about 15 cps, most preferably between about 10 and about 13 cps. The term
”jetting temperature” refers to the temperature of the ink at the print head and is typically about
°C to about 60°C, preferably about 35°C to about 45°C. The viscosity of the inks can for instance be
measured by a Brookfield DV—II+ viscometer, with small sample adapter, while using spindle S18, at
80 rpm.
In ular embodiments, the ink compositions suitable for use in the processes and products of the
t invention essentially comprise sub-micron particles of a heat ant inorganic pigment.
Preferably, the average size of the inorganic pigments is less than about 1.2um, preferably less than
about 0.9um, more able less than about 0.7um, most preferably, the average size of the
inorganic pigment les is below about 550 nanometers (0.55%). The term ”inorganic pigment”
refers to a t, which is at least partially inorganic. By a preferred embodiment the inorganic
pigments are metal oxides, which are a priori present in a form le for giving the desired
properties. Various metal oxides may be used such as chromium oxide, copper oxide, mix oxides
CuCr203 oxide (for black color), Red iron oxide (Pigment Red 101), Nickel antimony titanium yellow
rutile nt yellow 53), Cobalt Aluminate blue spinel (Pigment blue 28), etc.
In particular ments, wherein the color of the pigment in the ink compositions is white and
thus the pigment is a white pigment (such as for example titanium dioxide (Ti02)), the average size of
the pigment les is between about 0.17pm to about 0.25pm.
In particular ments of the present invention, the ink compositions suitable for use in the
processes and products of the present invention are essentially alkali-resistant, i.e. resistant to a pH
of about 8 or higher, such as resistant to a pH of about 9 or higher, such as ant to a pH of about
or higher, such as resistant to a pH of about 11 or higher, more particularly resistant to a pH of
higher than about 12 or higher than about 13.
wo 2016/146423 26
In particular embodiments of the present invention, the pigments in the ink compositions suitable for
use in the processes and products of the present invention are essentially alkali-resistant, i.e.
resistant to a pH of about 8 or higher, such as resistant to a pH of about 9 or higher, such as resistant
to a pH of about 10 or higher, such as resistant to a pH of about 11 or higher, more particularly
resistant to a pH of higher than about 12 or higher than about 13.
The liquid e present in the inks suitable for use in the present invention is liquid at room
temperature of about 15°C to about 28° C. According to certain embodiments, ”solvent-based ink” is
composed of at least one organic solvent (or a combination of l organic ts).
Alternatively, according to other ments, -based ink” is composed of a water-based
solution.
According to certain embodiments, the liquid vehicle is an organic solvent such as PM lene
glycol mono methyl ether), DPM (dipropylene glycol mono methyl ether), TPM (tripropylene glycol
mono methyl ether), PnB (propylene glycol mono n-butyl ether), DPnB (dipropylene glycol mono
butyl ether), TPNB (tripropylene glycol mono n—butyl , PnP (propylene glycol mono propyl
ether), DPnP (dipropylene glycol mono propyl ether), TPNB-H (propylene glycol butyl ether), PMA
(propylene glycol mono methyl ether acetate), Dowanol DB (Diethylene glycol mono butyl ether) or
other ethylene or propylene glycol ethers (Dow Chemical y, USA). The vehicle may also be a
e of two or more different organic solvents. In further particular embodiments, the liquid
vehicle or solvent present in the inks suitable for use in the present invention is a solvent—based ink,
such as an oil-based ition.
In particular embodiments, the solvent-based ink suitable for use in the products and processes of
the present invention comprises at least one inorganic or at least one white pigment, and at least
one solvent together with a dispersion agent.
In particular ments, the ink further comprises at least one dispersant or/and wetting agent,
such as Bykumen (solution of a lower molecular weight rated acidic polycarboxylic acid
ter and White spirit/lsobutanol=2/1), Disperbyk-166 (solution of a high molecular weight block
copolymer with pigment affinic groups and ypropylacetate/Butylacetate=1/4), Disperbyk—164
(solution of a high molecular weight block copolymer with pigment affinic groups and Butylacetate),
Disperbyk-130 (solution of polyamine amides of unsaturated polycarboxylic acids and
Alkylbenzene/Butylglycol=5/1), Disperbyk—182 (solution of a high molecular weight block copolymer
with pigment affinic groups and Methoxypropylacetate/Methoxy-
proppoxypropano|/Butylacetate=4/4/4), Disperbyk—163 (solution of high molecular weight block
wo 2016/146423 27
copolymer with pigment affinic groups, in xylene/butyl/acetate/methoxypropylacetate 3/1/1);
Disperbyk-161 (solution of a high molecular weight block mer with pigment affinic groups and
Methoxypropylacetate/Butylacetate=6/1), Disperbyk-101 ion of a salt of long chain polyamine
amides, polar acidic esters and Mineral spirit/Butylglycol 8/1), byk-160 (solution of a high
lar weight block copolymer with pigment affinic groups and /Butylacetate=6/1), BYK—P—
104 (solution of a lower molecular weight unsaturated polycarboxylic acid polymer and
Xylene/Diisobutylketone=9/1), BYK—P-104 S (solution of a lower molecular weight unsaturated
polycarboxylic acid polymer with a polysiloxane copolymer and Xylene/Diisobutylketone=9/1),
Disperbyk-180 (Alkylolammonium salt of a block copolymer with acidic groups), Disperbyk—110
(solution of a mer with acidic groups and Methoxypropyl acetate/Alkylbenzene=1/1), BYK-348
(polyether modified poly-dimethyl-siloxane), BYK-346 (solution of a polyether modified poly-
yl-siloxane in Dipropyleneglycol monomethylether), 1 (solution of an rylic
copolymer and dipropyleneglycol-monomethylether) (Chemie-BYK, Germany), BYK-306 (solution of a
polyether ed poly-dimethyl-siloxane and xylene/monophenylglyco|+7/2), BYK-358N (solution
of polyacrylate copolymer and alkyl benzenes), BYK-333 (polyether modified poly-dimethyl-siloxane),
Tego Dispers 650 (special modified polyether with pigment affinic ), Tego Dispers 652
(concentrate of a fatty acid derivative), Tego Dispers 710 (solution of a basic ne copolymer).
(TegoChemie Service, Germany), Solsperse 43000 (50% polymeric dispersant in water), Solsperse
40000 (84% polymeric sant in water with diethanolamine) (Avecia, UK). Some of these
dispersants is suitable for both solvent based and water based inkjet formulations and others for
solvent based or water based inks or both.
The ink, in accordance with the invention may comprise additional components, lly selected
from g agents, dispersing agents, defoamers, ants, rheology control agents, organic
polymers as binders and fixation agents which provide ”green strength” (such as polyacrylates or
polyvynilpyrrolidone, PVP) anticorrosive agents, coalescent agents, pH control agents and biocides.
The next step in the processes of the invention for producing an ink-jet printed fiber cement product
comprises drying the ink print, so as to obtain an ink-jet printed fiber cement t. While there
are different ways of drying or curing inks, an air-dryable oil-based ink comprising inorganic pigments
is preferred for use in the present invention.
In further particular embodiments, the processes for producing ink—jet printed fiber cement products
of the present invention comprise applying one or more layers of a radiation-curable second coating
composition on top of said one or more cured layers of a first coating composition and/or on top of
wo 2016/146423 28 2016/054814
said dried ink print. The radiation—curable second coating composition of the process according to
the present invention comprises at least one polymer having nically unsaturated double bonds,
which is radiation curable. Possible polymers for the radiation-curable coating compositions are in
ple any polymer which has ethylenically unsaturated double bonds and which can undergo
radical—initiated polymerization on exposure to UV radiation or on beam radiation.
The monomers having unsaturated double bonds such as acryl amide rs, meth acrylic acid
monomers, (meth) acrylic acid monomers, N - vinyl pyrrolidone and crotonic acid as long as they are
used in thejet inks, are preferred to be the polymerizable monomer.
Care should be taken here that the content of ethylenically unsaturated double bonds in the r
is sufficient to ensure effective crosslinking. The content of ethylenically unsaturated double bonds in
the is generally in the range from about 0,01 to about 1,0 mol/100g of polymer, more preferably
from about 0,05 to about 0,8 moi/100 g of polymer and most preferably from about 0,1 to about 0,6
moi/100 g of polymer. Suitable polymers are for example but not limited to polyurethane derivatives
which contain ethylenically unsaturated double bonds, such as polyurethane acrylates.
Besides the polymer, the radiation-curable coating composition may also contain a different
compound having a molecular weight of less than about 800 g/mol and capable of polymerization by
ic or free-radical pathways. These compounds have generally at least one ethylenically
unsaturated double bond and/or one epoxy group and a molecular weight being less than about 800
g/mol. Such compounds generally serve to adjust to the
desired working 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 contains
these only to a subordinate . Such compounds are therefore also termed reactive diluents. The
proportion of reactive ts, based on the total amount of polymer and the reactive diluent in the
radiation-curable preparation, is preferably in the range of about 0% to about 90% by weight, and
most ably in the range from about 5% to about 50% by .
red reactive diluents are the esterification products of di— or polyhydric alcohols with acrylic
and/or methacrylic acid. Such nds are generally termed polyacrylates or polyether acrylates.
Hexanediol diacrylate, tripropylene glycol diacrylate and trimethylolpropane triacrylate are
particularly preferred.
The radiation-curable coating compositions may also comprise polymers which have cationically
polymerizable groups, in particular epoxy . These include copolymers of ethylenically
unsaturated monomers, the copolymers ning, as comonomers, ethylenically unsaturated
yl ethers and/or glycidyl esters of ethylenically unsaturated carboxylic acids. They also include
the glycidyl ethers of up-containing polymers, such as OH-group-containing polyethers,
wo 2016/146423 29
ters, polyurethanes and novolacs. They include moreover the glycidyl esters of polymers
containing carboxylic acid groups. If it is desired to have a cationically polymerizable component, the
compositions may comprise, instead of or together with the cationically polymerizable polymers, a
low—molecular-weight, cationically polymerizable compound, for example a di- or polyglycidyl 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 itions comprise usual auxiliaries, such as ners, flow control
agents, defoamers, UV stabilizers, emulsifiers, surface tension reducers and/or protective colloids.
Suitable auxiliaries are well known to the person skilled in the coatings technology. Silicones,
ularly polyether modified polydimethylsiloxane copolymers, may be used as surface additives
to provide good substrate wetting and good anti—crater performance by reduction of surface tension
of the coatings. Suitable stabilizers encompass l UV absorbers, such as oxanilides, triazines,
benzotriazoles nable as TinuvinTM grades from Ciba Geigy) and benzophenones. These may be
used in combination with usual adical scavengers, for example sterically hindered amines, e.g.
2,2,6,6—tetramethylpiperidine and 2,6—di—tert-butylpiperidine (HALS compounds). Stabilizers are
usually used in amounts of from about 0,1% to about 5,0% by weight and preferably from about 0,3%
to about 2,5% by weight, based on the polymerizable components t in the preparation.
The processes of producing an ink—jet d fiber cement product of the t invention further
se the step of radiation curing the one or more layers of the applied radiation-curable second
coating ition. Such radiation curing of the coating compositions may include curing by heat
curing, dual—curing, UV curing, EB curing and other curing technologies within a thermoplastic or
thermosetting system.
If curing is performed by UV radiation, the preparations to be used comprise at least one
photoinitiator.
A distinction is to be made here between photoinitiators for free-radical curing mechanisms
(polymerization of ethylenically rated double bonds) and photoinitiators for cationic curing
mechanisms (cationic polymerization of ethylenically unsaturated double bonds or polymerization of
compounds containing epoxy groups). Photoinitiators are not needed for electron beam e
compositions.
Suitable photoinitiators for adical photopolymerization, i.e. polymerization of ethylenically
unsaturated
wo 2016/146423 30
double bonds, are benzophenone and benzophenone derivatives, such as ylbenzophenone
and 4-chlorobenzophenone, Michler’s ketone, ne, henone derivatives, such as 1-
benzoylcyclohexan-l-ol, 2-hydroxy-2,2- ylacetophenone and 2,2-dimethoxy
phenylacetophenone, benzoin and benzoin , such as methyl benzoin ether, ethyl benzoin ether
and butyl benzoin ether, benzil ketals, such as benzil dimethyl ketal, 2-methyl-1—[4—(methylthio)
phenyl]morpholinopropan-l-one, quinone and its tives, such as .beta.-
methylanthraquinone and tertbutylanthraquinone, 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 epoxy groups, are aryl diazonium salts, such as 4-methoxybenzenediazonium
hexafluorophosphate,
benzenediazonium luoroborate and toluenediazonium tetrafluoroarsenate, aryliodonium salts,
such as diphenyliodonium hexafluoroarsenate, arylsulfonium salts, such as triphenylsulfonium
hexafluorophosphate, benzene- and toluenesulfonium hexafluorophosphate and bis [4-
diphenylsulfoniophenyl] sulfide afluorophosphate, disulfones, such as diphenyl disulfone and
phenyI—4-tolyl disulfone, diazodisulfones, imidotriflates, benzoin tosylates, isoquinolinium salts, such
as N-ethoxyisoquinolinium hexafluorophosphate, phenylpyridinium salts, such as N-ethoxy
phenylpyridinium hexafluorophosphate, picolinium salts, such as N—ethoxy-Z-picolinium
hexafluorophosphate, ferrocenium salts, titanocenes and titanocenium salts.
The abovementioned photoinitiators are used, in amounts from about 0,05% to about 20% by
weight, preferably from about 0,1% to about 10% by weight and in particular from about 0,1% to
about 5% by weight, based on the polymerizable components of the radiation-curable ition.
The radiation-curable coating itions are applied in a known manner, e.g. by spraying,
trowelling, knife application, ng, rolling or pouring onto the the fiber cement product. It is also
conceivable that the preparation may be applied to the fiber cement product by hot-melt processes
or by powder-coating processes. The radiation-curable composition is preferably applied by roller-
coating. The ion-curable composition is usually applied to obtain a dry thickness in the range
from about 10 to about 100 um, preferably from about 50 to about 80 pm. The application may take
place either at room temperature or at elevated temperature, but preferably not above 100 °C.
wo 2016/146423 31
The radiation-curable coating composition may be cured by exposure to a UV radiation of
wavelength generally from about 200 nm to about 600 nm. Suitable examples of UV sources are high
and medium pressure mercury, iron, gallium or lead vapor lamps. Medium pressure mercury vapor
lamps are particularly preferred, e.g. the CK or CKl s from the company IST (Institut fiJr
Strahlungstechnologie). The radiation dose usually sufficient for crosslinking is in the range from
about 80 to about 3000 mJ/cm2. Any solvent present, in particular water, is dried out before the
curing in a te drying step preceding , for example by heating to temperatures in the
range from about 40°C to about 80 °C, or by exposure to IR radiation.
In case of electron beam curing, irradiation is performed with high-energy electrons (usually from
100 to 350 keV), by ng a high voltage to tungsten filaments inside a vacuum chamber), and the
actual curing step takes place in an inert, —free atmosphere.
The radiation-curable second coating compositions as used in the products and processes of the
present invention described herein are applied to at least part of the outer surface of a fiber cement
product using a brush, blade, roller, r (e.g., air-assisted or airless, electrostatic), vacuum
coater, curtain coater, flood coater or any suitable device that promotes an even distribution of the
paint formulation over the e, even if the surface is damaged, worn, or cracked. The
ition may be applied to provide a smooth surface, colored surface or textured surface. A
portion or an entire surface of the substrate may be coated at one time. In addition or as an
alternative, all or a portion of the e may be coated more than one time to achieve the desired
thickness, gloss, and/or surface effect. The amount of coverage obtained by a quantity of the paint
composition will vary depending on the desire and/or ion of the surface to be covered and the
ess of the coating applied.
In a fourth aspect, the present invention provides ink-jet printed fiber cement products obtainable by
the processes as described above, which t d fiber cement product at least comprise on at
least part of their outer surface:
- one or more cured layers of a first coating composition, at least comprising a binder and a pigment,
wherein said first coating composition is characterized by a pigment volume concentration of higher
than about 40%, and
- a dried ink print applied on top of said one or more cured layers of a first coating composition.
In particular embodiments, by using the methods as described above, these fiber cement products
may further comprise one or more ion-cured layers of a second coating ition applied on
wo 46423 32
top of said one or more cured layers of a first coating composition and/or on top of said dried ink
print.
In a fifth aspect, the present invention provides uses of a fiber cement products according to the
present invention or uses of ink-jet d fiber cement products according to the present invention
as a building material. These fiber cement ng materials may be porous materials comprising
one or more different materials such as a gypsum composite, cement composite, geopolymer
composite or other ites having an inorganic binder. The surface of the material may be
sanded, machined, extruded, molded or otherwise formed into any desired shape by various
processes known in the art. The fiber cement building materials may be fully cured, partially cured or
in the uncured ”green” state. Fiber cement building materials may r include gypsum board,
fiber cement board, fiber cement board reinforced by a mesh or continuous fibers, gypsum board
reinforced by short fibers, a mesh or continuous fibers, inorganic bonded wood and fiber composite
materials, geopolymer bonded wood and fiber boards, concrete g tile al, and fiber-
plastic composite material.
In particular ments, the fiber cement products of the invention are fiber cement sheets
produced by the processes of the present invention and can be used to provide an outer surface to
walls, both internal as well as external a building or construction, e.g. as facade plate, siding, etc.
EXAMPLES
It will be appreciated that the following examples, given for purposes of illustration, are not to be
construed as limiting the scope of this invention. Although only a few exemplary embodiments of this
invention have been described in detail above, those d in the art will readily appreciate that
many modifications are possible in the exemplary embodiments without materially ing from
the novel teachings and advantages of this invention. Accordingly, all such modifications are
intended to be included within the scope of this invention that is defined in the following claims and
all equivalents thereto. Further, it is ized that many embodiments may be conceived that do
not achieve all of the advantages of some ments, yet the absence of a particular advantage
shall not be construed to necessarily mean that such an embodiment is outside the scope of the
t invention.
Example 1: Production of fiber cement sheets according to the processes of the invention
wo 2016/146423 33
Fiber cement sheets were produced according to a conventional Hatschek process and cured
thereafter.
The sheets were subsequently coated with a first coating, namely a based acrylic coating
containing a white titandioxide pigment, having a composition as listed in Table 1 below. The
pigment volume concentration of this coating composition was about 62%.
The coating was cured by drying.
”/0 ‘ t
Binder
[FlleriExtend-er -—
-¢——
19:33.88
After drying, the coated surface of the sheets was subjected to inkjet printing with oil-based inks
comprising calcinated inorganic pigments glass-Itaca; yellow M 5118); orange-brown
(CIK-MA 5115) and blue (CIK-AZ 1114)). The ink prints were allowed to air-dry.
Finally, the printed surface of the sheets was coated with an UV e coating and UV cured.
The observed ink print pattern on all printed sheets was very clear and of high printing quality, i.e. no
ink bleeding, no jagged edges and no ink stains were detected.
y, the printed fiber cement sheets were subjected to a number of tests in order to characterize
their physical and chemical properties.
First, the coated sheets were subjected to an adhesion test (DIN ISO 2409), whereby adhesive tape is
d onto the coated surface. Thereafter the tape is quickly (and in one go) pulled off. It was
observed, as presented in Table 2, that 0% of the coating could be pulled off by the tape.
Also, a cross—cut test was done (DIN ISO 2409), y a right-angle lattice pattern is cut into the
coating, penetrating through to the substrate (i.e. surface of the fiber cement sheet). It was
observed that the edges of the cut lattice pattern were completely smooth and none of the squares
of the lattice were detached (classification GT 0; see Table 2)).
Furthermore, the sheets were tested under artificial weathering conditions (using a Xenon lamp) in
accordance with DIN 53 387). After the test, the print design was evaluated visually and the gloss of
wo 2016/146423 34
the sheets was measured and both parameters were compared with non—exposed samples. It could
be concluded that there were no color s and no visual gloss changes (Table 2).
Water penetration was also measured. No visual watermarks were ed (Table 2).
Chemical resistance of the coated fiber cement sheets against a number of different chemicals was
measured in accordance with DIN EN 2812—4:2007-5. The sheets were resistant against near all
chemicals tested.
Finally, the wet rub resistance test was performed in accordance with DIN EN ISO 11998, which
resulted in a loss of thickness of the sheets of about 6.5 pm (classification 2: scrubable).
Based on the above s, it can generally be ded that the fiber cement products of the
present ion are particularly well suited for being subjected to inkjet printing, unlike the prior
art fiber cement products up to now. This is due to the fact that the inventors have found that
applying a coating composition having a pigment volume concentration of higher than 40% increases
both the mity and the porosity of the outer surface of such products significantly so as to allow
quick absorbance and capturing of the ink drops applied during inkjet printing. Undesired ink stains,
ink bleeding and jagged edges of the ink n are hereby prevented and instead an l
printing quality is obtained.
Table 2
Tested ty Norm test Specified critical Results
values
Adhesion: DIN EN ISO 2409 Tape test: <15 % Tape test: 0% damage
- Tape test damage; Crosscut test: GT 0
— Crosscut test Crosscut test: <GT3
cial weathering (Xenon) DIN 53 387 Print design was No color fading even
evaluated visually after 4000h 9 OK
and the gloss was No visual gloss
measured (both changes either.
parameters were Measured Angles: 60°/85°
Values before: 26,3/30,4
compared to a non
Values after: 24,1/ 28,5
exposed sample)
9 OK
Coverage of the TC Water penetration No watermarks 9 OK
Chemical resistance DIN EN 2812- Resistant against
4:2007-5 nearly all tested
chemicals
Wet rub ance DIN EN ISO 11998 Loss of thickness
6,5p.m
Class 2: "Scrubable"
Claims (9)
1. An ink-jet printed fiber cement product, which t printed fiber cement product at least comprises on at least part of its outer surface: one or more cured layers of a first coating ition, at least comprising a binder and an alkali resistant pigment, wherein said first coating composition is characterized by an effective t volume concentration between 60 and 80%, wherein the effective t volume concentration can be calculated via the following mathematical formula: “effective pigment volume concentration” (expressed in %) = “effective PVC” ssed in %) = (volume of prime pigments)/(volume of prime pigments + volume of solid binder(s)) * 100 (expressed in %); and a dried ink print applied on top of said one or more cured layers of a first coating composition.
2. The fiber cement product according to claim 1, wherein said pigment sed in said first coating composition is a white pigment.
3. The fiber cement product ing to either of claims 1 or 2, wherein said binder is an acrylic polymer.
4. The fiber cement product according to claim 3, wherein said acrylic polymer is chosen from the group ting of styrene acrylic, siloxane acrylic, epoxy acrylic, polyester acrylic, polyuria acrylic and urethane acrylic.
5. The fiber cement product according to any one of claims 1 to 4, wherein said ink print is formed by using an ink comprising at least one inorganic pigment.
6. The fiber cement product according to any one of claims 1 to 5, further comprising one or more radiation-cured layers of a second coating composition applied on top of said one or more cured layers of a first coating composition and/or on top of said dried ink print.
7. A process for producing a fiber cement product, said process comprising: providing a fiber cement product; applying to at least part of the outer surface of said fiber cement one or more layers of a first coating composition at least comprising a binder and an -resistant pigment, wherein said first coating composition is characterized by an effective pigment volume concentration between 60 and 80%, wherein the effective t volume concentration can be calculated via the following mathematical formula: “effective t volume concentration” (expressed in %) = “effective PVC” (expressed in %) = (volume of prime pigments)/(volume of prime pigments + volume of solid binder(s)) * 100 (expressed in %); curing said one or more layers of said first coating composition so as to obtain a fiber cement t suitable for being subjected to inkjet-printing; applying an ink print on top of said one or more cured layers of said first coating composition by means of an inkjet-printer; and drying said ink print, so as to obtain an ink-jet printed fiber cement product.
8. The process according to claim 7, wherein said ink print is formed by using an ink comprising at least one inorganic pigment.
9. The process according to either of claims 7 or 8, further comprising: applying one or more layers of a ion-curable second coating composition on top of said one or more cured layers of a first coating composition and/or on top of said dried ink print; and radiation curing said one or more layers of a ion-curable second coating composition.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP15159046.0 | 2015-03-13 | ||
EP15159046.0A EP3067218A1 (en) | 2015-03-13 | 2015-03-13 | Ink-jet printing on fiber cement products |
PCT/EP2016/054814 WO2016146423A1 (en) | 2015-03-13 | 2016-03-07 | Ink-jet printing on fiber cement products |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ733584A NZ733584A (en) | 2021-01-29 |
NZ733584B2 true NZ733584B2 (en) | 2021-04-30 |
Family
ID=
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