US20020179219A1 - Composite product and method of manufacture - Google Patents

Composite product and method of manufacture Download PDF

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Publication number
US20020179219A1
US20020179219A1 US10/090,385 US9038502A US2002179219A1 US 20020179219 A1 US20020179219 A1 US 20020179219A1 US 9038502 A US9038502 A US 9038502A US 2002179219 A1 US2002179219 A1 US 2002179219A1
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United States
Prior art keywords
layer
functional
substrate layer
slurry
product
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Abandoned
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US10/090,385
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English (en)
Inventor
Basil Naji
John Cottier
Robert Lyons
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James Hardie Research Pty Ltd
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James Hardie Research Pty Ltd
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Priority claimed from AUPR3478A external-priority patent/AUPR347801A0/en
Priority claimed from AUPR3475A external-priority patent/AUPR347501A0/en
Priority claimed from AUPR3476A external-priority patent/AUPR347601A0/en
Priority claimed from AUPR3474A external-priority patent/AUPR347401A0/en
Priority claimed from AUPR3477A external-priority patent/AUPR347701A0/en
Application filed by James Hardie Research Pty Ltd filed Critical James Hardie Research Pty Ltd
Assigned to JAMES HARDIE RESEARCH PTY LIMITED reassignment JAMES HARDIE RESEARCH PTY LIMITED ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: COTTIER, JOHN SYDNEY, LYONS, ROBERT, NAJI, BASIL
Publication of US20020179219A1 publication Critical patent/US20020179219A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B28B1/522—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement for producing multi-layered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/40—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material
    • B28B7/46—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material for humidifying or dehumidifying
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/06—Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
    • C04B18/08—Flue dust, i.e. fly ash
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/06—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres reinforced
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/02—Coverings or linings, e.g. for walls or ceilings of plastic materials hardening after applying, e.g. plaster
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/12—Flooring or floor layers made of masses in situ, e.g. seamless magnesite floors, terrazzo gypsum floors
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482—Coating or impregnation materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S106/00—Compositions: coating or plastic
    • Y10S106/01—Fly ash
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/249932—Fiber embedded in a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249967—Inorganic matrix in void-containing component
    • Y10T428/249968—Of hydraulic-setting material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249971—Preformed hollow element-containing
    • Y10T428/249972—Resin or rubber element
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249986—Void-containing component contains also a solid fiber or solid particle
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/263—Coating layer not in excess of 5 mils thick or equivalent
    • Y10T428/264—Up to 3 mils
    • Y10T428/265—1 mil or less
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31652—Of asbestos
    • Y10T428/31667—Next to addition polymer from unsaturated monomers, or aldehyde or ketone condensation product
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]

Definitions

  • the present invention relates to composites and particularly, but not limited to, fibre reinforced building composites, and methods of manufacturing the same.
  • Fibre reinforced cement is an extremely popular building product.
  • FRC products have limited acoustic, thermal and fire retardant properties. They can exhibit limited workability and generally lie in the medium density range (around 1300 kg/m 3 ) or higher (compressed densities of around 1700 kg/m 3 ).
  • the properties of fibre cement are altered by addition of other materials eg different fibres, fillers etc or altered with different production techniques.
  • Such alterations to the FRC formulation can be expensive to develop in order to ensure no detrimental side effects arise from such new formulations.
  • Alterations in production methods or equipment are also expensive and time consuming to develop.
  • Such techniques also do not provide for true “tailoring” of the FRC product. It is, of course, inappropriate to shut down an entire production line, for example, to produce a small batch of FRC product tailored to a specific use.
  • the present invention provides a composite product comprising a substrate layer and one or more functional layers applied thereto, each functional layer including a mixture of hydraulic binder, dewatering agent wherein the quantity of dewatering agent is sufficient to permit de-watering of each functional layer through the substrate layer and any additional functional layer.
  • the present invention provides a method of manufacturing a composite product comprising:
  • step (v) optionally repeating steps (ii) through (iv), wherein the quantity of dewatering agent is sufficient to maintain porosity and thereby permit de-watering of each functional layer through the substrate layer and any additional functional layer.
  • the substrate layer is a fibre reinforced base material such as fibre reinforced cement.
  • This substrate layer provides a structural base on which additional functional layers may be added.
  • the functional layers may be added to both sides of the substrate layer but most preferably are added to one side which generally expose one side of the building board during production. Such a technique allows the aforementioned method to be applied to current FRC production techniques such as Hatschek.
  • the present applicants have developed a process for manufacture of a composite article to virtually any desired specification or use.
  • the present inventive composite and method starts with a simple water permeable substrate layer such as conventional fibre reinforced building board.
  • a simple water permeable substrate layer such as conventional fibre reinforced building board.
  • the base layer are added one or more functional layers, each functional layer being specifically tailored to provide the desired functionality.
  • the slurry formulation from which the functional layer is formed can include insulating materials such as rubber crumbs, vermiculite, perlite, gypsum, etc.
  • water permeability may be decreased by including water resistant polymers eg silanes, siloxane blends etc or pozzalanic materials such as silica fume, metakaoline, ultrafine fly ash etc.
  • water resistant polymers eg silanes, siloxane blends etc or pozzalanic materials such as silica fume, metakaoline, ultrafine fly ash etc.
  • Density modification of the functional layer can be accomplished by addition of suitable light weight materials such as cenospheres (ceramic hollow spheres), expanded polystyrene, vermiculite, perlite etc.
  • the inventive process enables various functional layers to be integrated into a single composite by appropriate slurry modification.
  • each functional layer has a reinforcing layer positioned therebetween.
  • the reinforcing layer may comprise fibre mesh or netting, and serves to improve the strength and durability of the composite product.
  • the reinforcing layer may comprise a thin fibre reinforced cementitious layer similar for instance to the base material.
  • a thin fibre reinforced cementitious layer similar for instance to the base material.
  • This provides for more efficient utilisation of such fibre reinforced layers, similar to sandwich composite technology.
  • a core area can be formed as the aforementioned functional layer with low fibre reinforcement.
  • Areas which require high fibre reinforcement due to high tensile strength ie surface or skin areas, can be covered by a fibre reinforced cementitious layer.
  • the thus formed fibre reinforced layers act as sandwich skins with a de-watered slurry functional layer acting as a sandwich core.
  • the described composite provides significant advantages over monolithic fibre reinforced composites. Firstly, by the aforementioned composite action, fibres can be positioned in areas where they are most required. This will, of course, lead to a reduction in the fibre reinforced volume of the product.
  • one of the most important advantages arising from preferred embodiments of the present invention is the ability to concentrate a particular functionality into a single layer.
  • any adjustments to the functional or structural aspects of the product au be diluted or diminished or unevenly spread throughout the product.
  • a top or finish coating layer can also be provided for the composite product by a fibre reinforced cementitious layer, a material similar or identical to the functional layer or any other product.
  • the top or finishing coating can be primarily an “aesthetic” layer of, say, ultrafine particle size or made from a sandable material to smooth the exterior surface of the composite product and thereby provide a finish/paint ready surface.
  • the dewatering agent serves to maintain sufficient porosity in the slurry and product to be coated to permit dewatering of the slurry through the product to be coated.
  • the dewatering agent is a particulate material such as fly ash, alumina trihydrate, silica flour, cenospheres (ceramic hollow spheres) or similar.
  • Fly ash is particularly preferred as it permits dewatering of the slurry within a few minutes.
  • Other particulate dewatering agents such as alumina trihydrate or silica flour may also be used, however, they increase the time required for dewatering of the slurry through the product to be coated.
  • the slurry applied to the product to be coated has a high water content.
  • the water content can be up to about 50%. This is in contrast to previous cementitious formulations which generally have a very high solids content.
  • the resultant product would be normally cured, steam cured or hydrothermally cured, ie autoclaved, and if required, sanded to a smooth flat finish.
  • the substrate layer to which the functional layers can be applied is virtually limitless provided the slurry can be dewatered through the substrate layer.
  • Cementitious and gypsum building boards are typical examples of suitable building products on which the coating can be applied.
  • the thickness of the functional layers would range from around 0.1 to 10 mm, preferably about 0.5 to 5 mm and most preferably about 1 to 3 mm.
  • the layer may have a depth of around 0.05 to 5 mm, preferably about 1 to 2 mm and most preferably about 0.5 to 1 mm.
  • the thus produced composite is comparable in its workability to monolithic (single layer) composites. It can be flexed, cut, drilled and fixed by nails etc to a frame without surface cracking or chipping.
  • hydroaulic binder refers to a pulverised material in the solid, dry state which, when mixed with water, yields plastic mixtures that are able to set and harden, for example a cement. Included within the definition are white, grey or pigmented cements and hydraulic limes.
  • cement includes hydraulic and alite cements such as portland cement, blended cements such as portland cement blended with fly ash, blast-furnace slag, pozzalans and the like and mixtures thereof, masonry cement, oil well cement, natural cement, alumina cement, expansive cements and the like, or mixtures thereof.
  • the quantity of binder in the formulation is preferably between about 10 to 50 wt % based on the total dry ingredients, more preferably about 15 to 40 wt % and most preferably about 20 to 30 wt %.
  • the fly ash used in the preferred embodiments provides a number of advantages including, particularly, as an aid to dewatering of the slurry as defined above.
  • powder ash refers to a solid powder having a chemical composition similar to or the same as the composition of material that is produced during combustion of powdered coal, ie about 25 to 60 wt % silica, about 10 to 30 wt % Al 2 O 3 , about 5 to 25 wt % Fe 2 O 3 , about 0 to 20 wt % CaO and about 0 to 5 wt % MgO.
  • the dewatering agent may include a coarse fraction fly ash which is greater than about 100 microns.
  • This coarse fraction fly ash includes bottom ash or similar products from coal combustion. There is an advantage to using these products over the aforementioned particle size fly ash since it is cheaper.
  • some reformulation of the slurry may be required to provide a suitable coating and appropriate dewatering characteristics when the dewatering agent is such a coarse fraction fly ash.
  • Fly ash particles are typically spherical and range in diameter from about 1 to 100 microns.
  • the fly ash comprises two components.
  • a first ‘larger’ size particles of fly ash with preferably about a 100 micron maximum size. This size range of fly ash is used in the slurry to aid in improving the dewatering characteristics of the slurry but also as a moderately reactive pozzalan.
  • the second ‘smaller’ fly ash size zone which preferably has about a 10 micron maximum size also adds an improving dewatering characteristic but is a more highly reactive pozzalan. This ‘smaller’ fly ash particle zone also improves the sanded surface quality of the finish layer.
  • the first fly ash comprises about 10 to 60 wt % of the formulation based on total dry ingredients, more preferably about 20 to 50 wt % and most preferably about 30 to 40 wt %.
  • the second fly ash component preferably provides about 5 to 30 wt % of the formulation based on total dry ingredients, more preferably about 10 to 25 wt % and most preferably about 15 to 20%.
  • the functional layers may optionally contain other additives such as fillers.
  • fillers may also be used to improve the dewatering characteristics of the slurry.
  • cenospheres high ceramic microspheres
  • wollastonite diatomite
  • ground rice hulls ground perlite or the like
  • fillers may also be used to provide additional benefits, for example calcium carbonates or alumina hydrates improve sandability and flexibility of the coated layer respectively.
  • Silica flour improves hardness of the sanded surface of the coating layer and the acoustic/thermal insulation properties of the layer can be improved by including rubber particles, vermiculite, perlite, shredded or expanded polystyrene or gypsum.
  • the fillers preferably comprise about 5 to 30 wt % of the formulation based on total dry ingredients, more preferably about 10 to 25 wt % and most preferably about 25 to 20 wt %.
  • the functional layers may also contain other organic additives.
  • Cement plasticising agents may be used to alter the rheology of the slurry. Suitable cement plasticising agents include melamine sulphonate formaldehyde condensates, naphthalene sulphonate formaldehyde condensates, naphthalene sulphonates, calcium lignosulphonates, sodium lignosulphonates, saccharose, sodium gluconate, sulphonic acids, carbohydrates, amino carboxylic acids, polyhydroxycarboxilic acids, sulphonated melomine and the like.
  • the amount of cement plasticiser of course will depend upon the fluidising ability of the particular plasticisers. Generally the quantity of plasticiser will be in the range of about 0.3 to 3 wt % and more preferably about 0.5 to 2 wt % based on the total of dry ingredients in the formulation.
  • Particularly preferred cement plasticisers are Melment F-10, a melamine formaldehyde sodium bisulphate polymer dispersant marketed by SKW-Trostburg in the form of a fine white powder.
  • Another suitable plasticiser is Neosyn, a condensed sodium salt of sulphonated naphthalene formaldehyde available from Hodgson Chemicals.
  • Another preferred component in the coating is a biopolymer which acts to enhance the flowability, segregation resistance and self levelling qualities of the cementitious slurry.
  • Particularly suitable bioplymers are xanathan gum and/or whelan gum, eg KELCO-CRETE, K1C 376 manufactured by Monsanto.
  • Latex may also be included in the formulation to improve adherence, elasticity, stability and impermeability of the functional layers.
  • the latex also improves flexibility of the formed composite.
  • the latex may be selected from the group consisting of acrylic latex, styrene latex, butadiene latex or mixtures thereof and is provided preferably in an amount between about 0.5 to 20%, more preferably about 1 to 15% and most preferably about 10% by weight of cement (on polymer solids basis) solids.
  • Vinyl polymers may also be incorporated into the formulation either in addition or as a substitute to the latex emulsions. Such vinyl polymers or equivalent polymeric materials enhance adhesion, resilience and flexural strength and abrasion resistance of the functional layer.
  • Preferred vinyl polymers include polyvinyl acetate or a copolymer vinyl acetate with another monomer such as ethylene.
  • a particularly preferred vinyl acetate resin is VINNAPAS LL5044 thermo plastic resin powder which contains a vinyl acetate-ethylene copolymer available from Wacker. Such powdered vinyl polymer is preferably provided in quantities similar to the latex emulsion referred to above.
  • one particular advantage arising from the preferred embodiments is the ability to treat the product to be coated by providing additives in the functional layer.
  • additives for instance, a waterproofing agent such as silane may be included in the formulation in excess of the functional layer requirements.
  • silane will be drawn into and through the base layer being coated thereby treating the base layer. This simultaneous treatment of the base layer as well as providing a functional attribute via the deposited layer is a valuable additional benefit arising from the aforedescribed method.
  • a slurry of the formulation is prepared by mixing the hydraulic binder, fly ash and other optional components with water.
  • the solids content in the slurry is preferably between about 50 and 90%, more preferably about 55 to 80% and most preferably about 60 to 70%.
  • the slurry is applied to the base layer by any convenient means such as brushes rollers, knives or sprays etc.
  • the slurry is designed to self level and form a uniform coating on the product.
  • the building product to be coated exhibits s certain degree of porosity causing the slurry to dewater and form a uniform deposited cementitious layer.
  • Time for dewatering can vary quite dramatically but normally occurs between about 10 and 90 seconds, depending on the porosity of the material to be coated, its water content and thickness and viscosity of the slurry formulation.
  • a vacuum may be used to reduce the slurry dewatering time if required. This is particularly useful when tailoring the coating process to the speed of a building product forming process, eg between about 40 to 45 seconds on a Hatschek production line.
  • the green laminate article comprising the building product plus coating is preferably precured for a short time, eg up to about 48 hours, then cured by air/moist curing at room temperature, steam curing between about 40 and 90° C. or autoclaving in a steam pressure vessel between about 120 and 200° C.
  • a curing time range between about 6 and 72 hours, preferably up to about 48 hours, is suitable.
  • the length of time chosen for curing is dependent on the formulation, the manufacturing process and form of the article.
  • the aforementioned examples provide a composite comparable in workability to monolithic or single layer composites. They can be flexed, cut, drilled or fixed by nails or the like to a frame without surface cracking or chipping.
  • the surface is ‘finish-ready’ and remains smooth, flat, crack-free and with low permeability even when used in a curved configuration.
  • Each example provided excellent interlaminer bond between the base sheet and coating exhibiting good composite action, compatibility and resistance to delamination.
  • the applicants have developed a unique process which allows them to combine fibre reinforced layers with functional dewatered slurry layers optional reinforced with a wide range of synthetic or natural fibres, eg polypropylene, glass, PVA, cellulose fibres etc.
  • the outcome of the aforementioned method is to produce a fibre reinforced composite with strength, water resistance, incombustibility of fibre cement with a low density, surface finish and insulation properties of, for example, gypsum board.
US10/090,385 2001-03-02 2002-03-04 Composite product and method of manufacture Abandoned US20020179219A1 (en)

Applications Claiming Priority (10)

Application Number Priority Date Filing Date Title
AUPR3475 2001-03-02
AUPR3478A AUPR347801A0 (en) 2001-03-02 2001-03-02 Coatings for building products
AUPR3475A AUPR347501A0 (en) 2001-03-02 2001-03-02 Spattering apparatus
AUPR3476A AUPR347601A0 (en) 2001-03-02 2001-03-02 Additive for dewaterable slurry
AUPR3474 2001-03-02
AUPR3474A AUPR347401A0 (en) 2001-03-02 2001-03-02 A composite product
AUPR3477 2001-03-02
AUPR3478 2001-03-02
AUPR3476 2001-03-02
AUPR3477A AUPR347701A0 (en) 2001-03-02 2001-03-02 A method and apparatus for forming a laminated sheet material by spattering

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US10/090,299 Expired - Lifetime US7396402B2 (en) 2001-03-02 2002-03-04 Coatings for building products and dewatering aid for use with same
US10/090,387 Expired - Lifetime US6749897B2 (en) 2001-03-02 2002-03-04 Coatings for building products and methods of using same
US10/090,560 Abandoned US20020189499A1 (en) 2001-03-02 2002-03-04 Coating for building products and composite products incorporating same
US10/090,388 Expired - Fee Related US6824715B2 (en) 2001-03-02 2002-03-04 Method and apparatus for forming a laminated sheet material by spattering
US10/090,375 Abandoned US20030000424A1 (en) 2001-03-02 2002-03-04 Coatings for building products and formulations for use with same
US10/090,338 Abandoned US20020189500A1 (en) 2001-03-02 2002-03-04 Additive for dewaterable slurry
US10/090,561 Expired - Fee Related US7704316B2 (en) 2001-03-02 2002-03-04 Coatings for building products and methods of making same
US10/090,385 Abandoned US20020179219A1 (en) 2001-03-02 2002-03-04 Composite product and method of manufacture
US10/090,362 Abandoned US20020170466A1 (en) 2001-03-02 2002-03-04 Additive for dewaterable slurry and method of manufacturing and improving slurry containing same
US10/090,376 Expired - Fee Related US6692570B2 (en) 2001-03-02 2002-03-04 Spattering apparatus
US10/090,406 Expired - Lifetime US6893751B2 (en) 2001-03-02 2002-03-04 Composite product
US11/128,778 Abandoned US20050208287A1 (en) 2001-03-02 2005-05-13 Composite product
US11/634,285 Abandoned US20070077436A1 (en) 2001-03-02 2006-12-04 Composite product
US12/691,505 Expired - Lifetime US8153245B2 (en) 2001-03-02 2010-01-21 Composite product

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US10/090,299 Expired - Lifetime US7396402B2 (en) 2001-03-02 2002-03-04 Coatings for building products and dewatering aid for use with same
US10/090,387 Expired - Lifetime US6749897B2 (en) 2001-03-02 2002-03-04 Coatings for building products and methods of using same
US10/090,560 Abandoned US20020189499A1 (en) 2001-03-02 2002-03-04 Coating for building products and composite products incorporating same
US10/090,388 Expired - Fee Related US6824715B2 (en) 2001-03-02 2002-03-04 Method and apparatus for forming a laminated sheet material by spattering
US10/090,375 Abandoned US20030000424A1 (en) 2001-03-02 2002-03-04 Coatings for building products and formulations for use with same
US10/090,338 Abandoned US20020189500A1 (en) 2001-03-02 2002-03-04 Additive for dewaterable slurry
US10/090,561 Expired - Fee Related US7704316B2 (en) 2001-03-02 2002-03-04 Coatings for building products and methods of making same

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US10/090,362 Abandoned US20020170466A1 (en) 2001-03-02 2002-03-04 Additive for dewaterable slurry and method of manufacturing and improving slurry containing same
US10/090,376 Expired - Fee Related US6692570B2 (en) 2001-03-02 2002-03-04 Spattering apparatus
US10/090,406 Expired - Lifetime US6893751B2 (en) 2001-03-02 2002-03-04 Composite product
US11/128,778 Abandoned US20050208287A1 (en) 2001-03-02 2005-05-13 Composite product
US11/634,285 Abandoned US20070077436A1 (en) 2001-03-02 2006-12-04 Composite product
US12/691,505 Expired - Lifetime US8153245B2 (en) 2001-03-02 2010-01-21 Composite product

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CN100391883C (zh) 2008-06-04

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