WO2008076241A1 - Engineered composite building materials and methods of making same - Google Patents
Engineered composite building materials and methods of making same Download PDFInfo
- Publication number
- WO2008076241A1 WO2008076241A1 PCT/US2007/025210 US2007025210W WO2008076241A1 WO 2008076241 A1 WO2008076241 A1 WO 2008076241A1 US 2007025210 W US2007025210 W US 2007025210W WO 2008076241 A1 WO2008076241 A1 WO 2008076241A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- impregnating agent
- building material
- fibers
- substrate
- composite building
- Prior art date
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- 239000004566 building material Substances 0.000 title claims abstract description 67
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- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 4
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- MSRJTTSHWYDFIU-UHFFFAOYSA-N octyltriethoxysilane Chemical compound CCCCCCCC[Si](OCC)(OCC)OCC MSRJTTSHWYDFIU-UHFFFAOYSA-N 0.000 description 4
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- YKTNISGZEGZHIS-UHFFFAOYSA-N 2-$l^{1}-oxidanyloxy-2-methylpropane Chemical group CC(C)(C)O[O] YKTNISGZEGZHIS-UHFFFAOYSA-N 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
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- QYZFTMMPKCOTAN-UHFFFAOYSA-N n-[2-(2-hydroxyethylamino)ethyl]-2-[[1-[2-(2-hydroxyethylamino)ethylamino]-2-methyl-1-oxopropan-2-yl]diazenyl]-2-methylpropanamide Chemical compound OCCNCCNC(=O)C(C)(C)N=NC(C)(C)C(=O)NCCNCCO QYZFTMMPKCOTAN-UHFFFAOYSA-N 0.000 description 2
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- BEQKKZICTDFVMG-UHFFFAOYSA-N 1,2,3,4,6-pentaoxepane-5,7-dione Chemical compound O=C1OOOOC(=O)O1 BEQKKZICTDFVMG-UHFFFAOYSA-N 0.000 description 1
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- BLZSRIYYOIZLJL-UHFFFAOYSA-N ethenyl pentanoate Chemical compound CCCCC(=O)OC=C BLZSRIYYOIZLJL-UHFFFAOYSA-N 0.000 description 1
- UIWXSTHGICQLQT-UHFFFAOYSA-N ethenyl propanoate Chemical compound CCC(=O)OC=C UIWXSTHGICQLQT-UHFFFAOYSA-N 0.000 description 1
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- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 1
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- SRSFOMHQIATOFV-UHFFFAOYSA-N octanoyl octaneperoxoate Chemical compound CCCCCCCC(=O)OOC(=O)CCCCCCC SRSFOMHQIATOFV-UHFFFAOYSA-N 0.000 description 1
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- 125000005634 peroxydicarbonate group Chemical group 0.000 description 1
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- BWJUFXUULUEGMA-UHFFFAOYSA-N propan-2-yl propan-2-yloxycarbonyloxy carbonate Chemical compound CC(C)OC(=O)OOC(=O)OC(C)C BWJUFXUULUEGMA-UHFFFAOYSA-N 0.000 description 1
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- YPVDWEHVCUBACK-UHFFFAOYSA-N propoxycarbonyloxy propyl carbonate Chemical compound CCCOC(=O)OOC(=O)OCCC YPVDWEHVCUBACK-UHFFFAOYSA-N 0.000 description 1
- 125000001436 propyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
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- 238000010561 standard procedure Methods 0.000 description 1
- 125000004079 stearyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- KDYFGRWQOYBRFD-UHFFFAOYSA-N succinic acid Chemical class OC(=O)CCC(O)=O KDYFGRWQOYBRFD-UHFFFAOYSA-N 0.000 description 1
- WYKYCHHWIJXDAO-UHFFFAOYSA-N tert-butyl 2-ethylhexaneperoxoate Chemical compound CCCCC(CC)C(=O)OOC(C)(C)C WYKYCHHWIJXDAO-UHFFFAOYSA-N 0.000 description 1
- GJBRNHKUVLOCEB-UHFFFAOYSA-N tert-butyl benzenecarboperoxoate Chemical compound CC(C)(C)OOC(=O)C1=CC=CC=C1 GJBRNHKUVLOCEB-UHFFFAOYSA-N 0.000 description 1
- 125000000999 tert-butyl group Chemical group [H]C([H])([H])C(*)(C([H])([H])[H])C([H])([H])[H] 0.000 description 1
- 238000001029 thermal curing Methods 0.000 description 1
- NMEPHPOFYLLFTK-UHFFFAOYSA-N trimethoxy(octyl)silane Chemical compound CCCCCCCC[Si](OC)(OC)OC NMEPHPOFYLLFTK-UHFFFAOYSA-N 0.000 description 1
- 238000001771 vacuum deposition Methods 0.000 description 1
- 239000010455 vermiculite Substances 0.000 description 1
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Classifications
-
- 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
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
-
- 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
- C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
- C04B20/10—Coating or impregnating
- C04B20/1018—Coating or impregnating with organic materials
- C04B20/1029—Macromolecular compounds
-
- 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
-
- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
-
- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/46—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with organic materials
- C04B41/48—Macromolecular compounds
- C04B41/483—Polyacrylates
-
- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/46—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with organic materials
- C04B41/48—Macromolecular compounds
- C04B41/488—Other macromolecular compounds obtained otherwise than by reactions only involving unsaturated carbon-to-carbon bonds
- C04B41/4884—Polyurethanes; Polyisocyanates
-
- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/46—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with organic materials
- C04B41/49—Compounds having one or more carbon-to-metal or carbon-to-silicon linkages ; Organo-clay compounds; Organo-silicates, i.e. ortho- or polysilicic acid esters ; Organo-phosphorus compounds; Organo-inorganic complexes
- C04B41/4905—Compounds having one or more carbon-to-metal or carbon-to-silicon linkages ; Organo-clay compounds; Organo-silicates, i.e. ortho- or polysilicic acid esters ; Organo-phosphorus compounds; Organo-inorganic complexes containing silicon
- C04B41/4922—Compounds having one or more carbon-to-metal or carbon-to-silicon linkages ; Organo-clay compounds; Organo-silicates, i.e. ortho- or polysilicic acid esters ; Organo-phosphorus compounds; Organo-inorganic complexes containing silicon applied to the substrate as monomers, i.e. as organosilanes RnSiX4-n, e.g. alkyltrialkoxysilane, dialkyldialkoxysilane
-
- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/46—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with organic materials
- C04B41/49—Compounds having one or more carbon-to-metal or carbon-to-silicon linkages ; Organo-clay compounds; Organo-silicates, i.e. ortho- or polysilicic acid esters ; Organo-phosphorus compounds; Organo-inorganic complexes
- C04B41/4905—Compounds having one or more carbon-to-metal or carbon-to-silicon linkages ; Organo-clay compounds; Organo-silicates, i.e. ortho- or polysilicic acid esters ; Organo-phosphorus compounds; Organo-inorganic complexes containing silicon
- C04B41/495—Compounds having one or more carbon-to-metal or carbon-to-silicon linkages ; Organo-clay compounds; Organo-silicates, i.e. ortho- or polysilicic acid esters ; Organo-phosphorus compounds; Organo-inorganic complexes containing silicon applied to the substrate as oligomers or polymers
- C04B41/4961—Polyorganosiloxanes, i.e. polymers with a Si-O-Si-O-chain; "silicones"
-
- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
-
- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/60—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
- C04B41/61—Coating or impregnation
- C04B41/62—Coating or impregnation with organic materials
- C04B41/63—Macromolecular compounds
-
- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/60—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
- C04B41/61—Coating or impregnation
- C04B41/62—Coating or impregnation with organic materials
- C04B41/64—Compounds having one or more carbon-to-metal of carbon-to-silicon linkages
-
- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/60—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
- C04B41/61—Coating or impregnation
- C04B41/70—Coating or impregnation for obtaining at least two superposed coatings having different compositions
- C04B41/71—Coating or impregnation for obtaining at least two superposed coatings having different compositions at least one coating being an organic material
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D1/00—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
- C09D1/06—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances cement
- C09D1/08—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances cement with organic additives
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- 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
- C04B2111/0062—Gypsum-paper board like 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
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/27—Water resistance, i.e. waterproof or water-repellent materials
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
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- 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
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
- Y10T428/2495—Thickness [relative or absolute]
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- 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.]
- Y10T428/249962—Void-containing component has a continuous matrix of fibers only [e.g., porous paper, etc.]
- Y10T428/249964—Fibers of defined composition
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- 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.]
- Y10T428/249962—Void-containing component has a continuous matrix of fibers only [e.g., porous paper, etc.]
- Y10T428/249964—Fibers of defined composition
- Y10T428/249965—Cellulosic
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- 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
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- 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
- Y10T428/259—Silicic material
Definitions
- This invention generally relates to composite building materials, and in particular, to a composite building material having an engineered cement-polymer matrix.
- Fiber-reinforced composite materials particularly fiber cement
- fiber cement have become popular for use as a building material.
- fiber cement is preferred over the more conventional materials such as wood, metal, or plastics.
- fiber cement has better water resistance and is also less prone to rotting, cracking or splitting.
- fiber cement articles may be painted on-site using any color of a standard acrylic-based exterior paint typically applied on wood
- Conventional concrete sealers do not work well with cementitious, gypsum, or other inorganic composite materials containing cellulose, glass, steel or polymeric fibers. Such conventional sealers typically have high viscosity and tend to form a film on the surface of the composite material; they are not formulated to penetrate into subsurface layers of a composite and do not block pores therein from moisture.
- the terms "impregnate,” “impregnating” and “impregnation” shall mean to cause an additive compound to be imbued, permeated or saturated in one or more subsurface regions of a building material including the core matrix of the building material.
- Embodiments of the invention may include an engineered composite building material that comprises a cementitious substrate having a pre-determined porosity and a sub-surface region formed in the substrate.
- the sub-surface region comprises a cement- polymer matrix configured to reduce moisture absorption of the building material.
- the cement-polymer matrix may comprise a polymeric impregnating agent chemically bonded to hydroxyl functional groups in the substrate. Thickness of the sub-surface region may be determined by viscosity of the impregnating agent and the porosity of the cementitious substrate. In one embodiment, the thickness of the impregnated subsurface region is about 10 microns, preferably 50 microns, preferably 100 microns or greater.
- the thickness of the impregnated subsurface region is about 100 microns and more preferably 150, 200, 250, 300 microns or greater. In yet another embodiment, the thickness of the impregnated subsurface region is substantially the same as a thickness of the fiber cement matrix.
- the impregnating agent is selected from the group consisting of one or more isocyanates, epoxies, acrylics, organics with unsaturated double bonds, and mixtures thereof
- the impregnating agent comprises an isocyanate compound with one or more blocked functional groups.
- Impregnating agents may also be selected from the group consisting of silanes and low viscosity oligomers or monomers and combinations thereof
- the impregnating agent is a low viscosity material which, in an uncured state, has a viscosity of less than about 300 centipoise (cps) at 25° C.
- the impregnating agent further comprises a polymerization initiator selected from the group consisting of organic peroxides, azo compounds, and mixtures thereof
- Impregnating agents may also include a catalyst selected from the group consisting of tertiary amines, metal salts, and combinations thereof
- the impregnating agent (or agents) selected forms non-hydrolysable bonds with free hydroxyl and other functional groups dispersed in the fiber cement matrix.
- the fiber cement matrix comprises cellulose fibers and the impregnating agent forms non-hydrorysable bonds with free hydroxyl groups attached to the cellulose fibers.
- the fiber cement matrix comprises polymer fibers selected from the group consisting of polyvinyl alcohol (PVA), modified polypropylene (PP), polyethylene (PE), and polyester fibers.
- the impregnating agent comprises an autogenously curable compound.
- the composite building material further includes an exterior coating formed on an exterior surface of the building material.
- the exterior coating is may be selected from the group consisting of paints, topcoats, primers, sealers, and combinations thereof.
- the impregnating agent forms chemical bonds with the exterior coating to improve the bond strength between the coating and the fiber cement matrix.
- the impregnated subsurface region increases the modulus of elasticity of the building material by about 5% or more.
- the impregnated subsurface region reduces the water absorption of the building material by more than about 10% of the water absorption value of the same material without treatment and increases the freeze thaw cycles by more than about 15% of the same material without treatment based on the retention of required material properties such as, for example, Modulus of rupture (MOR), modulus of elasticity (MOE), and Z direction tensile strength.
- MOR Modulus of rupture
- MOE modulus of elasticity
- Z direction tensile strength Z direction tensile strength.
- the building material may be selected from the group consisting of gypsum boards, fiber cement boards, fiber cement boards reinforced by a mesh or continuous fibers, gypsum boards reinforced by short fibers, a mesh or continuous fibers, inorganic bonded wood and fiber composite materials, geopolymer bonded wood and fiber boards, concrete roofing tile material, and fiber-plastic composite materials.
- inventions may provide a method of forming an engineered composite building article.
- One or more methods comprise forming a cementitious substrate and incorporating a curable impregnating agent into a subsurface region of the substrate in a manner such that the impregnating agent is allowed to penetrate into the sub-surface region of the substrate to a predetermined depth.
- the method may further include curing the impregnating agent after the impregnating agent has penetrated into the substrate to the predetermined depth.
- the curable impregnating agent has a viscosity of less than or equal to about 500 cps at 25° C.
- the impregnating agent may be autogenously cured.
- the method further comprises reducing the viscosity of the curable impregnating agent prior to incorporating the agent in the subsurface region
- incorporating the curable impregnating agent in the subsurface region comprises applying the material to an exterior surface of the substrate after the substrate is cured and allowing the impregnating agent to penetrate into the cured substrate to a predetermined depth.
- the predetermined depth is at least about 10 microns. In another embodiment, the pre-determine depth is at least about 100 microns.
- incorporating the curable impregnating agent in the cementitious substrate comprises combining the curable impregnating agent with ingredients for forming the cementitious substrate and forming a shaped green article, wherein the curable impregnating agent is distributed throughout at least a portion of the shaped green article.
- incorporating the curable impregnating agent in the cementitious substrate comprises combining ingredients for forming the cementitious substrate to form a shaped green article and then applying the curable impregnating agent to an exterior surface of the shaped green article.
- the curable impregnating agent preferably has a viscosity of about 500 cps or less at 25° C, more preferably about 300 cps or less at 25° C.
- the method further comprises applying a protective coating to the building article.
- the method further comprises curing the curable impregnating agent under a process condition selected from the group consisting of ambient temperature, elevated temperature, cryogenic temperature, vacuum, pressure, atmospheric pressure, UV, infrared, electron beam, microwave or other radiations, and combinations thereof.
- the curable impregnating agent may be applied to the cementitious substrate by a process selected from group consisting of vacuum coater, dipping, flooding coater, direct roller coater, sprayers, fountain coater, brush coater, sea saw coater, and curtain coater, or any other coaters or reaction vessels, and combinations thereof
- the cementitious substrate may be cured by a process selected from the group consisting of air curing, water curing (hot or ambient), microwave curing, autoclave curing, and combinations thereof
- embodiments may provide an engineered composite building material having a sub-surface region comprising a cement-polymer matrix, wherein the cement-polymer matrix has a thickness of at least 10 microns and is configured to reduce moisture absorption of the building material by about 15% or more as compared to an equivalent composite building material without the sub-surface region.
- embodiments may provide a composite building material having one or more impregnating agents therein.
- the impregnating agents are preferably capable of forming chemical and/or mechanical bonds with one or more components of the composite building material. These chemical and/or mechanical bonds are preferably freeze-thaw resistant and not hydrolysable, therefore, enhancing the durability of the material.
- the impregnating agent is selected to form chemical and/or mechanical bonds with a cementitious matrix, with at least one type of reinforcing fiber, and/or with an exterior coating such as the sealer, primer, topcoat or paint.
- the composite building material is a fiber reinforced inorganic composite material comprising an inorganic binder, reinforcing fibers, a reactive impregnating agent, one or more aggregates, and one or more fillers or additives.
- the inorganic binder may include but is not limited to Portland cement, high alumina cement, lime, ground granulated blast furnace slag cement, and high phosphate cement, or mixtures thereof
- the aggregates may include but are not limited to ground silica sand, amorphous silica, micro silica, diatomaceous earth, coal combustion fly and bottom ashes, microspheres of glass, plastic beads and microspheres, ceramic, polymers, pre-reacted calcium silicate hydrate particles, calcium carbonate particles, rice hull ash, blast furnace slag, granulated slag, steel slag, mineral oxides, mineral hydroxides, clays, magnasite or dolomite, metal oxides and hydroxides, polymeric beads, or mixtures thereof
- the reinforcing fibers may include but are not limited to various forms of cellulose fibers such as chemical, mechanical or thermal-mechanical pulps, ceramic fiber, glass fiber, mineral wool, steel fiber, and synthetic polymer fibers such as polyamides, polyester, polyprop
- the fillers may include but are not limited to low density organic and inorganic inert particles.
- the additives may include but are not limited to density modifiers, dispersing agents, silica fume, geothermal silica, fire retardants, thickeners, pigments, colorants, dispersants, foaming agents, flocculating agents, waterproofing agents, organic density modifiers, aluminum powder, kaolin, alumina trihydrate, mica, metakaolin, calcium carbonate, wollastonite, polymeric resin emulsions, and mixtures thereof.
- the impregnating agents include, but are not limited to, a low viscosity isocyanate, low viscosity of epoxy, low viscosity organics with unsaturated double bonds, silanes or their low viscosity oligomers, low viscosity acrylics, other low viscosity polymers, and their emulsions or dispersions.
- the impregnating agents may include one component or more of the above chemicals. They may also include the above chemicals in as a solid or with water, solvent and other diluents.
- the viscosity of the impregnating agent is less than about 500 cps at 25° C, and less than about 200 cps at 25° C and more preferably less than 250, 200, 175, 150, 125, 100, 75, 50, 25, 10, 1 or 0.1 cps at 25° C.
- the impregnating agent may react with free hydroxyl (-OH) or other reactive groups dispersed throughout the matrix material, on the surface of the reinforcing fibers and/or other components, and/or on subsequently applied coatings.
- Embodiments of certain implementations may also include a method of forming a durable finished fiber cement material comprising an impregnating agent and a finishing coating.
- the finishing coating may be applied to the fiber cement material before or after curing of the impregnating agent.
- the finishing coating on the uncured impregnated fiber cement substantially eliminates or minimizes evaporation of the impregnating agent during its curing, which may provide the advantage of reducing VOC in production and improving the retention of the impregnating agent.
- the impregnating agents such as silane and isocyanate may react with -OH group in the fiber cement and with moisture in the substrate and in the air, and thus may be cured under ambient conditions.
- the formulation may comprise ingredients for forming a fiber reinforced cementitious substrate and an impregnating agent comprising a curable polymeric compound having a viscosity of less than about 500 cps at 25° C.
- the impregnating agent is selected to form non-hydro lysable chemical bonds with one or more ingredients for forming the fiber reinforced cementitious substrate.
- the ingredients for forming the fiber reinforced cementitious substrate comprises fibers selected from the group consisting of cellulose fibers, PVA fibers, PP fibers, PE fibers, polyester fibers, carbon fibers, steel fibers, and combinations thereof [0020] Certain embodiments may advantageously provide finished fiber cement building materials with the desirable characteristics of reduced water absorption, reduced rate of water absorption, lower water migration, and lower water permeability. Certain embodiments may also impart the final products with enhanced paint adhesion, freeze-thaw resistance, chemical resistance, salt resistance, and better mechanical properties as compared to conventional fiber cement products.
- FIGURE 1 is a cross sectional schematic view of a composite building article of one embodiment showing a subsurface region containing one or more impregnating agent that is able to form chemical and/or mechanical bonds with one or more components of the building material;
- FIGURES 1A-1C illustrate one embodiment of the composite building article in the form of a building plank
- FIGURE 2 illustrates a process for forming a composite building article according to one implementation as described herein;
- FIGURE 3 is a cross section photograph of an impregnated fiber cement specimen made according to a embodiment.
- FIGURE 4 is a chart comparing the MOE results after freeze-thaw cycling of an impregnated fiber cement specimen with the results of an equivalent fiber cement specimen without any impregnation.
- Described herein is a product and method that overcomes previous problems.
- the method and building material products herein provide improvements, particularly by extending the durability of any coating on a building material, including a fiber reinforced composite material
- FIGURE 1 schematically illustrates a cross sectional view of an engineered composite building material 100 of at least one embodiment.
- the building material 100 comprises a substrate 102 having one or more engineered sub-surface regions 104 and a coating 106 formed on an exterior surface 108 of the substrate 102.
- the engineered sub-surface regions 104 comprise a cement-polymer composite matrix designed to provide the building material with improved physical and mechanical properties.
- the substrate 102 of the engineered composite building material 100 in FIGURE 1 is porous and may be based on a variety of different materials such as gypsum composite, cement composite, geopolymer composite, or other composites having an inorganic binder.
- the substrate 102 may be sanded, machined, extruded, molded or otherwise formed into any desired shape by various processes known in the art.
- the substrate 102 may be fully cured, partially cured or in the uncured "green" state.
- a variety of different fiber cement compositions and methods of making fiber cement substrates may be used for these applications, such as those described in Australian Patent No. AU515151, International Publication No. WO 0169547, and International Publication No. WO 9845222, which are hereby incorporated by reference in their entirety for all purposes.
- the engineered sub-surface regions 104 in the substrate 102 illustrated in FIGURE 1 preferably comprise a matrix formed of a cementitious material and a polymer.
- the cement-polymer matrix comprises an intimate blend of fiber cement and one or more impregnating agents that are capable of forming chemical and/or mechanical bonds with the binder, the filler, the aggregate, reinforcement fibers, and/or any other components of a fiber cement composite matrix.
- the one or more impregnating agents may also be capable of forming chemical and/or mechanical bonds with the exterior coating 106 of the material, thereby improving the adhesion between the coating 106 and the substrate 102.
- Some embodiments may have chemical bonding only, mechanical bonding only, or a combination of chemical and mechanical bonding.
- the impregnating agents preferably penetrate the voids and interstices of the porous fiber cement substrate 102 and form chemical and/or mechanical bonds with the fiber cement without requiring the aid of radiation or thermal curing.
- the impregnating agents are chemically bonded to the hydroxyl (-OH) or other reactive groups present in the cement or on the fibers in the substrate.
- the impregnating agents may be autogenously cured, and/or cured with the help of curing aids, heat or radiation.
- the impregnating agents may include but are not limited to low viscosity isocyanates, low viscosity epoxies, low viscosity organics with unsaturated double bonds, silanes or their low viscosity oligomers, low viscosity acrylics, other low viscosity polymers and their emulsions or dispersions.
- the number, shape, distribution, and thickness of the sub-surface regions 104 may be engineered based on the intended final use of the composite material.
- the thickness of each sub-surface region 104 is pre-selected and controlled by the porosity of the substrate, the amount of the impregnating agent introduced to the porous substrate, and the viscosity of the impregnating agent at room temperature.
- the engineered sub-surface region extends substantially throughout the entire substrate and the thickness of the sub-surface region is substantially the same as the thickness of the substrate.
- the thickness of the sub-surface region is between about 0.1% to about 100%, preferably between about 0.4%- 100%, of the thickness of the substrate.
- the thickness of the sub-surface region may be greater than or equal to about 10 microns, or may be greater than or equal to about 100 microns. In yet another embodiment, the sub-surface region may be between about 0.006 to about 5.0 inches (0.15- 127 millimeters) thick.
- the exterior coating 106 of the building material 100 shown in FIGURE 1 may comprise a variety of different finishing and/or protective coatings such as paint, topcoat, primer, sealer, radiation curable coating, or thermally curable coating.
- the cement-polymer composite matrix in the sub-surface region 104 of the substrate 102 forms chemical and/or mechanical bonds with the exterior coating to enhance the adhesion of the coating to the substrate 102.
- the cement- polymer composite matrix is capable of forming chemical bonds with the -OH groups in the coating.
- the building material 100 illustrated in FIGURE 1 may be used in a wide variety of building articles including but not limited to cladding panels, sheets, boards, planks, trims, shakes, decking, fascia, slates, fencing pickets o ⁇ boards, and pipes.
- the composition of the impregnating agent used to form the sub-surface region 104 comprises an aromatic or aliphatic isocyanate compound that has a pH between about 6.5 and 7.5, and is preferably between about 6.8 and 7.2.
- the isocyanate compound present in the composition has an -NCO functional group that is approximately between 5% and 50% by weight of the total weight of the polymer, and may be between about 10% and 33% by weight.
- the isocyanate polymer has a functionality (number of NCO per molecule) of preferably between about 2.0 and 3.5, with an average functionality of at least 2.0, and has a viscosity between 3 to 500 cps at 25 0 C.
- Suitable liquid isocyanate terminated compositions include but are not limited to Rubinate M and Rubinate 9433 available from Huntsman Polyurethanes of Arlington Heights, Michigan; Mondur MR, Mondur MRS, Mondur MRS-4, and Mondur MR200, available from Bayer Corporation, Pittsburgh, Pennsylvania; Isonate 2134, Papi 94, Papi 27, Papi 20 available from Dow Chemical of Midland, Michigan; and mixtures thereof
- Suitable aliphatic isocyanates include but are not limited to Desmodur XP-7100 (Bayer), Desmodur N-3400 (Bayer) and Desmodur N-3300 (Bayer); and mixtures thereof
- the composition of the impregnating agent also comprises one or more catalysts known in the art such as tertiary amines, metal salts, and any combinations thereof.
- the metal salts may include, for example, tin carboxylate, organosilicon titanates, alkyl titanates, bismuth carboxylates, zinc carboxylates, zinc-based salt, tin-based salt catalyst and the like.
- the system comprises approximately 0.005% to 5% of catalyst by weight.
- the catalyst is capable of catalyzing a reaction between the isocyanate and hydroxyl functional groups in the fiber cement in the presence of moisture so as to form chemical bonds between the isocyanate compounds in the mixture and the hydroxyl functional groups in the substrate.
- the catalyst present in the system is a bismuth-based salt having a bismuth concentration between approximately 0.3% to 20% by weight.
- the isocyanate compound further comprises a plasticizer that reduces the viscosity of the impregnating agent.
- a plasticizer such as, for example, alkyl phthalates (dioctylphthalate or dibutylphthalate), trictyl phosphate, epoxy plasticizers, toluene-sulfamide, chloroparaffins, adipics acid esters, castor oil, toluene and alkyl naphthalenes may be used for a polyurethane system
- the amount of plasticizer used may be between about 0% and 90% by weight.
- the isocyanate compound is emulsified with water before applications.
- the isocyanate compounds have -NCO functional groups that are initially blocked and then activated after applications.
- the impregnating agents may also include low viscosity monomers including single functional and poly-functional organics with unsaturated double bonds in one molecule. These components impregnate and bond well on fiber cement substrates.
- the mono- functional components may be, for example, styrene, methylstyrene, halogen styrenes, Ci-C 4 alkyl styrenes, vinyl butyl ether, vinyl toluene, vinyl acetate, vinyl esters of C 3 -Ci 8 monocarboxylic acids, such as vinyl propionate, vinyl butyrate, vinyl valerate, vinyl hexanoate, vinyl 2-ethylhexanoate, vinyl decanoate, vinyl laurate, vinyl stearate, and vinyl esters of Versatic acids (Versatic acids are generally branched, aliphatic carboxylic acids having 5 to 11 carbon atoms), methyl (meth)acrylate, ethyl (meth)acrylate, prop
- the poly-functional components preferably have at least two unsaturated double bonds in one molecule.
- a polymerization initiator is added to organics with unsaturated double bonds.
- organic peroxides may be used as an initiator: (1) ketone peroxides, such as methyl ethyl ketone peroxide, cyclohexanone peroxide, 3,3,5-trimethylcyclohexanone peroxide, methylcyclohexanone peroxide, methylacetoacetate peroxide and acetylacetone peroxide; (2) peroxyketals, such as 1,1- bis(tert-butylperoxy)-3,3,5-trimethylcyclohexane, 1 ,l-bis(tert-butylperoxy) cyclohexane, 2,2-bis(tert-butylperoxy)octane, n-butyl-4,4-bis(tert-butylperoxy)valerate and 2,2-bis(tert- butylperoxy)butane; (3) hydroperoxides, such as tert-butyl hydroperoxide, cumene hydroperoxide, diiso
- azo compounds may also be used as polymerization initiators: (9) azonitrile compounds, such as azobisisobutylonitrile, 2,2'-azobis(4-methoxy- 2,4-dimethylvaleronitrile), l,l'-azobis (cyclohexane- 1-carbonitrile), l-(l-cyano-l- methylethyl) azoformamide and 2-phenylazo-4-methoxy-2,4-dimethylvaleronitrile; (10) azoamidine compounds, such as 2,2'-azobis(2-methylpropionamidine) dihydrochloride; (11) cyclic azoamidine compounds, such as 2,2'-azobis-2-(2-imidazolin-2-yl) propane; (12) azoamide compounds, such as 2,2'-azobis(2-methyl-n-l,l-bis(hydroxymethyl)-2- hydroxyethyl propyonamide) and 2,2'-azobis (2-methyl-n
- Another class of the impregnating agents is silane, including but not limited to: silanes, n-octyltriethoxysilane, n-octyltrimethoxysilane, alkoxylsilanes, alkylalkoxysilanes with 1 to 18 carbons in the alkyl chain, halide organo silanes, carboxylated organosilanes, epoxyalkoxylsilane, silicone emulsions, and mixtures thereof.
- the impregnating agent for fiber cement comprises a combination of isocyanate, silane and components with double bonds.
- Another impregnating agent comprises a combination of isocyanate with other low viscosity plasticizers such as ethers or esters or others.
- the viscosity of the impregnating agents selected may be adjusted so that the impregnating agents may also be applied as an exterior coating such as protective sealer to the fiber cement article.
- FIGURE IA illustrates an embodiment that includes a building plank 110, having a predetermined volume, length, width, and thickness.
- Building plank 1 10 is 4 to 16 feet (1.2- 4.9 meters) in length, and preferably 6 to 12 feet (1.8-3.7 meters) in length; 2 inches to about 4 feet (0.05-1.2 meters) in width, preferably 3 inches to 12 inches (0.07-0.3 meters) in width and 1/8 inches to 6 inches (0.003-0.15 meters) in thickness, preferably 1 A inch to 1 inch (6-2.5 centimeters) in thickness.
- Building plank 110 may contain one or more voids within its volume.
- Building plank 110 may be used, for example, as an exterior cladding plank, cladding panel, roofing shingle, fencing plank, fencing panel or other covering for a building. Building plank 110 may also be cylindrical in shape and used as a pipe or column. [0042] FIGURE IB depicts cross section X-X of building plank 110, comprising porous substrate 102, finishing coating 106, impregnated region 104 and a sealer material 108. Impregnated region 104 extends from at least one surface of building plank 100 to a predetermined depth into the porous substrate 102, preferably at least 0.002 inches (0.05 millimeters) and more preferably at least 0.005 inches (0.1 rnillimeters).
- Impregnated region 104 may be continuously coextensive along the entire length of building plank 110, or extend from one end of building plank 110 to a predetermined point along its length. [0043] In one embodiment, where the building plank is a fencing plank or panel, the impregnated region 104 extends between 0.1 inch and 12 inches (0.25-30.5 centimeters) from one end of building plank 110, more preferably between 4 and 8 inches (10-20 centimeters).
- the regions of building plank 110 that do not comprise an impregnated region 104 instead comprise, as shown in cross section Y-Y of FIGURE 1C, porous substrate 102, finishing coating 106 and sealer 108.
- Sealer 108 may comprise any type of film- forming polymeric material, but is preferably an acrylic, acrylic copolymer, or isocyanate based sealer.
- FIGURE 2 illustrates a process 200 for manufacturing an engineered composite building material according to one embodiment.
- the engineered composite building material is made in the form of a fiber cement cladding panel.
- the process 200 to block 210 in which a fiber cement substrate is formed.
- the fiber cement substrate is preferably manufactured in accordance with known or available fiber cement compositions and manufacturing techniques.
- the fiber cement composition may generally fall within the ranges set out in Table 1 below.
- the binder may comprise ordinary Portland cement type I but may also comprise other inorganic binders such as gypsum, geopolymer, or other inorganic cements.
- the aggregate may comprise milled quartz, amorphous silica, perlite, vermiculite, synthetic calcium silicate hydrate, diatomaceous earth, rice hull ash, fly ash, bottom ash, blast furnace slag, granulated slag, steel slag, mineral oxides, mineral hydroxides, clays, magnasite or dolomite, polymeric beads, metal oxides and hydroxides, calcium carbonate, inorganic and organic microspheres, or mixtures thereof [0047] Fibers include various forms of cellulose fibers, such as bleached or unbleached Kraft pulp.
- fibers may be used other forms of fibers.
- suitable fibers are ceramic fiber, glass fiber, mineral wool, steel fiber, and synthetic polymer fibers such as poryamides, polyester, polypropylene, polymethylpentene, polyacrylonitrile, polyacrylamide, viscose, nylon, PVC, PVA, rayon, glass ceramic, carbon, or any mixtures thereof
- the fibers may also include cellulose fibers with hydrophobic treatments, biocide treatments, or such as those disclosed in PCT Patent Applications WO 0228796 and WO 0228795, which are both hereby incorporated by reference in their entirety for all purposes.
- additives may be optionally incorporated into the fiber cement composition including but not limited to density modifiers, dispersing agents, silica fume, geothermal silica, fire retardant, viscosity modifiers, thickeners, pigments, colorants, dispersants, foaming agents, flocculating agents, water- proofing agents, organic density modifiers, aluminum powder, kaolin, alumina trihydrate, mica, metakaolin, calcium carbonate, wollastonite, polymeric resin emulsions, hydrophobic agents, or mixtures thereof
- a fiber cement green sheet is produced using the Hatschek process.
- the Hatschek process uses a series of rotating drum sieves to deposit sequential layers of de-watered slurry onto an absorbent conveyer and accumulate them on a size roll until the desired sheet thickness has been achieved.
- the green sheets may also be produced using other suitable methods such as, for example, extrusion, casting, moulding, Mazza, Magnani, Fourdrinier and roll press processes.
- sub-surface regions comprising cement-polymer composite matrix may be formed in the fiber cement substrate by impregnating the substrate with one or more impregnating agents described herein.
- the impregnating agents may be applied while the fiber cement substrate is still in the green state or optionally applied to fully cured fiber cement.
- the impregnating agent may be applied using standard coating techniques such as spraying, roll coating, flooding, vacuum coating, and the like.
- the fiber cement substrate may be immersed in the impregnating agent for a predetermined amount of time.
- the impregnating agent is a low viscosity isocyanate, silane, acrylics, and components with double bond or combinations thereof
- the impregnation may be carried out under pressure or vacuum, cold or hot.
- the impregnation may also be implemented at a moisture enriched o ⁇ moisture-free environment.
- the impregnating agent is formulated with a sufficiently low viscosity, preferably less than about 500 cps at 25° C, more preferably less than about 250, 200, 175, 150, 125, 100, 75, 50, 25, 10, 1 or 0.1 cps at 25° C, so as to enable the impregnating agent to penetrate the pores and interstices of the fiber cement matrix.
- the impregnating agents may also be mixed in the fiber cement composition prior to forming the green sheet.
- the impregnating agent may form a durable mechanical and/or chemical bonds with one more components of the fiber cement substrate such as the cementitious matrix, the reinforcement fibers, the binder, or the aggregates.
- the bonds are formed autogenously, without the need for added thermal or radiation energy.
- the cement-polymer matrix in the sub-surface region may be cured at various pre-selected temperature and pressure conditions after the impregnating agent has been deposited in the pores and interstices of the fiber cement matrix.
- the cement-polymer matrix may be cured at a temperature of less than about 100° C and at a pressure of between about 10 atm - 20 atm.
- the cement-polymer matrix may be cured at a pressure of between about 50- 200 millibars.
- the cement-polymer matrix is cured at cryogenic temperature conditions or elevated temperature conditions.
- an optional coating, laminate or other protective material may be applied to at least one surface of the fiber cement substrate such that the coating or laminate may form a substantially continuous film upon the surface of the article.
- the coating or laminate reacts with at least some of the impregnating agent in the sub-surface region to form a durable bond between the substrate and the impregnating agent, and between the impregnating agent and the coatings on the top.
- the coating, laminating, or other protective material is applied to the fiber cement article before the impregnating agent cures as described at block 230. The coating or laminate may then, in certain implementation, be cured using standard methods known or available in the art.
- Fiber cement specimens (10 mm x 25 mm x 25 mm) were made in accordance with the following formulation: about 35% by weight of Portland Cement, about 57% by weight of aggregate silica, and about 8% by weight of cellulose fibers and using methods described in U.S. Patent No. 6,676,744 which is hereby incorporated by reference in its entirety for all purposes.
- the fiber cement specimens were dried in oven at a temperature of about 105° C for 15 minutes.
- Each of the dried fiber cement specimens was weighed before impregnation.
- Each fiber cement specimen was subsequently immersed in an impregnating agent specified in Table 2 for 10 minutes at 72° F + 2° F under atmospheric pressure. Paper towels were used to remove the excess impregnating agents from the surface of the specimens after impregnation.
- the impregnated fiber cement specimens were weighed. The impregnation loading was calculated based on the following formula:
- Table 2 illustrates the impregnation loading of the fiber cement specimens loaded with different impregnating agents and the results of 24-hour water absorption tests of each impregnated fiber cement samples after curing.
- the impregnating agents include Prosil 9202, which contains primarily octyltriethoxysilane and available from Clariant LSM of Jacksonville, Florida; SR 239 which is a methacrylate monomer and available from Sartomer Company, Inc.
- the first coat of paint was dried in a 60° C oven for about 4 min.
- the dry thickness of the first coating was about 0.002" to 0.004" (0.05-0.1 mm).
- the second coat was dried in a 105° C oven for about 2 min.
- the dry thickness of the second coating was about 0.001" to 0.003" (0.025-0.075 mm).
- Test peel adhesion of paint with 3M 250 masking tape was conducted after the finished fiber cement sample was cured in lab condition for 7 days.
- Table 5 shows that the raw fiber cement (without any impregnating agent or undercoat) has 60-90 % of paint peeled off by the tape when the specimen was saturated with water. But the same fiber cement impregnated with anywhere between about 0.0005" and 0.002" (0.013-0.05 mm) thick of Rubinate M did not show any paint peeling off by the tape. These results show that Rubinate M on the surface of fiber cement substantially affects bonding of the paint on the fiber cement article. Other isocyanates such as 0.002"
- Example 6 was prepared by applying impregnating agents to 5/16" x 4"x 5" (0.8 x
- Table 6 illustrates that impregnating agent aliphatic isocyanate Desmondur XP 7100 (which is available from Bayer Corp.) also improves the adhesion between paint and fiber cement plank. 0.01% of bismuth and zinc based catalyst such as Bicat 8 from Shepherd Chemical Company, OH, was mixed in
- EXAMPLE 7 Improvement on mechanical properties. Six sides of a 5/16" x 5"x 7.5" (0.8 x 12.7 x 19 cm) fiber cement plank (Selected Cedarmill texture, James Hardie Building Products of Fontana, California) with moisture content of about 18 to 20% were coated with an impregnating agent comprising about 0.0005" to 0.002" (0.013-0.05 mm) of Rubinate M. 0.01% of bismuth and zinc based catalyst such as Bicat 8 from Shepherd Chemical Company, OH was mixed in Rubinate M. After the Rubinate M was cured at ambient condition for 7 days, the specimens were immersed in water for 48 hrs. The planks were then tested for modules of elasticity (MOE). The results in Table 7 show that the thin layer of impregnating agent comprising Rubinate M on fiber cement slightly increased the stiffness of the fiber cement plank. The MOE values increase slightly with increased thickness of Rubinate M on fiber cement.
- the engineered composite building material of the embodiments provide certain improved physical and chemical properties as compared to an equivalent conventional composite building material without the engineered sub-surface regions.
- a composite building material with the engineered sub-surface regions has improved moisture absorption characteristics.
- the composite building material having an impregnation loading of about 100% provides about 15%, more preferably about 25%, reduction in moisture absorption as compared to an equivalent building material without the engineered sub-surface region.
- the engineered composite building material also provides the material with improved adhesion to paint and other exterior coatings such that the peel failure is reduced from about 60%- 90% failure rate to about 0% failure rate.
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- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Structural Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Inorganic Chemistry (AREA)
- Architecture (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
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Abstract
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NZ577617A NZ577617A (en) | 2006-12-13 | 2007-12-10 | Engineered composite building materials and methods of making same |
EP07862702.3A EP2122074A4 (en) | 2006-12-13 | 2007-12-10 | Engineered composite building materials and methods of making same |
AU2007334517A AU2007334517B2 (en) | 2006-12-13 | 2007-12-10 | Engineered composite building materials and methods of making same |
JP2009541318A JP5227332B2 (en) | 2006-12-13 | 2007-12-10 | Processing composite building materials |
CA 2671996 CA2671996C (en) | 2006-12-13 | 2007-12-10 | Engineered composite building materials and methods of making same |
IL199237A IL199237A0 (en) | 2006-12-13 | 2009-06-08 | Engineered composite building materials and methods of making same |
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US11/638,624 US8415009B2 (en) | 2006-12-13 | 2006-12-13 | Engineered composite building materials and methods of making same |
US11/638,624 | 2006-12-13 |
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EP (1) | EP2122074A4 (en) |
JP (2) | JP5227332B2 (en) |
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CA (1) | CA2671996C (en) |
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US20080141908A1 (en) | 2008-06-19 |
IL199237A0 (en) | 2010-03-28 |
EP2122074A1 (en) | 2009-11-25 |
CA2671996A1 (en) | 2008-06-26 |
JP5227332B2 (en) | 2013-07-03 |
JP2013151419A (en) | 2013-08-08 |
AU2007334517B2 (en) | 2014-02-06 |
US20130183505A1 (en) | 2013-07-18 |
EP2122074A4 (en) | 2014-04-02 |
WO2008076241A9 (en) | 2009-09-24 |
AU2007334517A2 (en) | 2010-01-07 |
JP2010513056A (en) | 2010-04-30 |
TW200839065A (en) | 2008-10-01 |
US8415009B2 (en) | 2013-04-09 |
AU2007334517A1 (en) | 2008-06-26 |
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US8906500B2 (en) | 2014-12-09 |
NZ577617A (en) | 2011-12-22 |
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