Classifications

• • 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
  • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
  • B28B11/08—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads
  • B28B11/0818—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads for roughening, profiling, corrugating
• • 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
  • E04C2/043—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 of plaster
• • 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
  • E04C2/044—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 of concrete
• • 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
  • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
  • E04C2/32—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material
  • E04C2/324—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material with incisions or reliefs in the surface
• • 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
  • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
  • E04C2/32—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material
  • E04C2/326—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material with corrugations, incisions or reliefs in more than one direction of the element
• • 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
  • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
  • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
  • E04F13/0871—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having an ornamental or specially shaped visible surface
• • 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
  • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
  • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
  • E04F13/14—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass
  • E04F13/147—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass with an outer layer imitating natural stone, brick work or the like
• • 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
  • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
  • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
  • E04F13/14—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass
  • E04F13/148—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass with an outer layer of asbestos cement or the like
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/02—Flooring or floor layers composed of a number of similar elements
  • E04F15/02177—Floor elements for use at a specific location
  • E04F15/02183—Floor elements for use at a specific location for outdoor use, e.g. in decks, patios, terraces, verandas or the like
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/02—Flooring or floor layers composed of a number of similar elements
  • E04F15/08—Flooring or floor layers composed of a number of similar elements only of stone or stone-like material, e.g. ceramics, concrete; of glass or with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass

Definitions

• the present invention relates to the field of composite building materials, such as building sheets or panels having a textured surface.
• the present invention relates to composite building sheets with a textured surface as well as to methods for the production thereof and applications thereof as roofing, facade, flooring or decking elements.
• Building elements are permanently exposed to a variety of external weathering conditions, including rain, frost, UV radiation etc. These weathering effects typically cause products and materials to become dirty, which results in an esthetically unattractive sight. Moreover, and even more importantly, weathering typically causes the exposed surface of these building materials to become slippery, due to for example moss and algae growth in combination with humidity and/or frost. Accordingly, especially in the case of flooring and decking elements but also during repair or replacement of roofing elements, there is a serious risk that people slip and fall.
• Wooden surfaces have the inherent problems of moss and fungi growth, rotting, splitting, splintering and termite damage. Wood therefore needs to be treated regularly and still has a relatively limited life-time of about 15 years. Moreover, the higher quality wood types are tropical wood species originating from the rain forest and thus do not provide an eco-friendly solution. Wood-plastic composite surfaces also suffer from moss and fungi growth and the polymer component is vulnerable to UV degradation. Concrete, on the other hand, has an inherent tendency to crack when subjected to adverse and variable weather conditions and humidity.
• the object of the present invention is to provide all-round esthetically appealing and strong composite building materials that are resistant to deterioration from exposure to external elements and that have an increased safety for those moving about on the surface of such materials.
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions characterized in that the distance x (as measured perpendicularly to the plane X of the building element) between the highest point of a projection and the lowest point of a depression is between 400 pm and 2000 pm.
• the total surface area of said irregularly textured surface is increased by 0,1% to 15% as compared to a non-textured surface area of the same material and with the same dimensions as the irregularly textured surface.
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions characterized in that the distance d (as measured perpendicularly to the plane X of the building element) between the highest point of a projection and the lowest point of a depression is between 500 pm and 1000 pm, preferably between 600 pm and 800 pm.
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions characterized in that the total surface area of said irregularly textured surface is increased by 1% to 0,5% as compared to a non-textured surface area of the same material and with the same dimensions as the irregularly textured surface.
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions characterized in that the total surface area of said irregularly textured surface is increased by 1% to 5% as compared to a non-textured surface area of the same material and with the same dimensions as the irregularly textured surface.
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions, characterized in that: the distance y (as measured perpendicularly to the plane X of the building element) between the highest point of a projection and a reference base plane Y has a value between 100 pm and 600 pm; the distance z (as measured perpendicularly to the plane X of the building element) between the lowest point of a depression and a reference base plane Y has a value between 100 pm and 600 pm; wherein said reference base plane Y is positioned parallel to the plane X of the building element and cross-sections said projections in the middle of the average distance d between all projections and all depressions on said textured surface (as measured perpendicularly to the plane X of the building element).
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions, characterized in that: the distance y (as measured perpendicularly to the plane X of the building element) between the highest point of a projection and a reference base plane Y has a value between 200 pm and 400 pm; the distance z (as measured perpendicularly to the plane X of the building element) between the lowest point of a depression and a reference base plane Y has a value between 200 pm and 400 pm; wherein said reference base plane Y is positioned parallel to the plane X of the building element and cross-sections said projections and depressions in the middle of the average distance d between all projections and all depressions on said textured surface (as measured perpendicularly to the plane X of the building element).
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions, characterized in that the surface comprises between 50 and 250 projections per dm 2 . In further particular embodiments, the textured surface comprises between 100 and 200 projections per dm 2 .
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions, wherein the cross-sectional area formed by a cross-section of the projections of the textured surface and a plane Z is between 200 and 800mm 2 / dm 2 of textured surface, wherein plane Z is positioned parallel to plane X of the building element and cross-sections the projections at 3/4 of the average distance d between all projections and all depressions on said textured surface (wherein the average distance d is the average of distances as measured perpendicularly to the plane X of the building element).
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions, wherein the total volume of the projections tops formed above the cross-section of these projections of the textured surface and a plane Z is between 50 and 150mm 3 / dm 2 of textured surface, wherein plane Z is positioned parallel to plane X of the building element and cross-sections the projections at 3/4 of the average distance d between all projections and all depressions on said textured surface (wherein the average distance d is the average of distances as measured perpendicularly to the plane X of the building element).
• the present invention provides a composite building material, having at least one irregularly textured surface, wherein said surface is characterized by a developed interfacial area surface Sdr of between 0,001 and 0,050.
• the present invention provides a composite building material, having at least one textured surface comprising a plurality of projections and depressions, wherein said textured surface is hydrophobated.
• the present invention provides a composite building material, having at least one textured surface comprising a plurality of projections and depressions, wherein said plurality of projections and depressions have an irregular non-geometric shape.
• the present invention provides a composite building material, which is a cement-bonded composite material or a gypsum-bonded composite material.
• the composite building material is chosen from the group consisting of fiber cementitious material, calcium silicate-based material or gypsum-based material.
• the present invention provides a composite building material, which is a facade element, a roofing element, a flooring element or a decking element.
• the present invention provides a composite building material, which is a building sheet or a building panel.
• the present invention provides a method for producing a composite building material having at least one textured surface comprising a plurality of projections and depressions, wherein said method comprises the steps of: a) Providing a composite building material, and b) Texturing at least one surface of said composite building material by applying a mechanical pressure.
• texturing can be done by treating at least one surface of said composite building material by brushing, sand blasting abrasive blasting or any other suitable texturing step at a suitable pressure.
• the present invention provides uses of the building material according to the present invention as a fagade element, a roofing element, a flooring element or a decking element.
• Figure 1 is a full picture of the top surface of a textured fiber cement product according to the present invention.
• Figure 2 is a perspective view on the top surface of a textured fiber cement product according to the present invention.
• Figure 3 is a detail picture of a corner with textured top surface of a textured fiber cement product according to the present invention.
• Figure 4 is a drawing of a cross-section of a textured surface is shown, indicating the following parameters:
• the fiber cement slurry as used in the context of the present invention may also further comprise other components, such as but not limited to, limestone, chalk, quick lime, slaked or hydrated lime, ground sand, silica sand flour, quartz flour, amorphous silica, condensed silica fume, microsilica, metakaolin, wollastonite, mica, perlite, vermiculite, aluminum hydroxide, pigments, anti-foaming agents, flocculants, and other additives.
• other components such as but not limited to, limestone, chalk, quick lime, slaked or hydrated lime, ground sand, silica sand flour, quartz flour, amorphous silica, condensed silica fume, microsilica, metakaolin, wollastonite, mica, perlite, vermiculite, aluminum hydroxide, pigments, anti-foaming agents, flocculants, and other additives.
• Fiber(s) present in the fiber cement slurry as described herein may be for example process fibers and/or reinforcing fibers which both may be organic fibers (typically cellulose fibers) or synthetic fibers (polyvinyl alcohol, polyacrylonitrile, polypropylene, polyamide, polyester, polycarbonate, etc.).
• organic fibers typically cellulose fibers
• synthetic fibers polyvinyl alcohol, polyacrylonitrile, polypropylene, polyamide, polyester, polycarbonate, etc.
• cement present in the fiber cement slurry as described herein may be for example but is not limited to Portland cement, cement with high alumina content, Portland cement of iron, trass-cement, slag cement, plaster, calcium silicates formed by autoclave treatment and combinations of particular binders.
• predetermined and predefined as used herein when referring to one or more parameters or properties generally mean that the desired value(s) of these parameters or properties have been determined or defined beforehand, i.e. prior to the start of the process for producing the products that are characterized by one or more of these parameters or properties.
• cementitious as in “cementitious product” or “cementitious material” as used herein refers to any product or material comprising cement, such as but not limited to Portland cement, cement with high alumina content, Portland cement of iron, trass-cement, slag cement, plaster, calcium silicates formed by autoclave treatment and combinations of particular binders.
• cement in the products of the invention is Portland cement.
• fiber cement product refers to products at least comprising fibers and cement.
• the fiber cement products as used in the context of the present invention may also further comprise other components, such as but not limited to, limestone, chalk, quick lime, slaked or hydrated lime, ground sand, silica sand flour, quartz flour, amorphous silica, condensed silica fume, microsilica, metakaolin, wollastonite, mica, perlite, vermiculite, aluminum hydroxide, pigments, anti foaming agents, flocculants, and other additives.
• a "(fiber cement) sheet” as used herein, also referred to as a panel or a plate, is to be understood as a flat, usually rectangular element, a fiber cement panel or fiber cement sheet being provided out of fiber cement material.
• the panel or sheet has two main faces or surfaces, being the surfaces with the largest surface area.
• the sheet can be used to provide an outer surface to walls, both internal as well as external a building or construction, e.g. as fagade plate, siding, etc.
• fiber cement layer refers to any flat, optionally substantially rectangular, layer or cake essentially consisting of a fiber cement composition and having a thickness of at least about 1 mm, in particular between about 1 mm and 200 mm, more particularly between about 2 mm and about 150 mm, most particularly between about 4 mm and about 100 mm, such as between about 8 mm and about 10 mm.
• Hatschek (fiber cement) layer or a “(Hatschek) fiber cement product” as used herein refer to a fiber cement layer (as defined herein) or a fiber cement product, respectively, which are produced according to a Hatschek process, which at least comprises the steps of:
• fiber cement film refers to such a thin layer of fiber cement being applied onto the felt transport belt by one or more sieves rotating in a fiber cement slurry that is present in one or more vats of the Hatschek process.
• series of thin fiber cement layers are produced on the one or more sieves from the Hatschek machine and subsequently superimposed and transferred from the one or more sieves to the transport belt, resulting in one or more uncured Hatschek fiber cement layers after accumulation on an accumulation roll.
• a fiber cement film in the context of the present invention, it is to be understood that this term encompasses, where applicable, both the meaning of one single fiber cement film having a thickness of between about 0.01 mm and about 0.9 mm, such as in particular between about 0.05 mm and about 0.5 mm, such as between about 0.1 mm and about 0.4 mm, such as about 0.3 mm. (i.e.
• one thin layer of fiber cement also called a mono-layer, a single layer or a primary layer, that is applied onto the felt transport belt by a sieve from a vat of the Hatschek process
• a layer comprising two or more superimposed fiber cement layers each having a thickness of between about 0.01 mm and about 0.9 mm, such as in particular between about 0.05 mm and about 0.5 mm, such as between about 0.1 mm and about 0.4 mm, such as about 0.3 mm (i.e. two or more superimposed thin layers of fiber cement applied onto the felt transport belt by two or more sieves from a vat of the Hatschek process).
• a fiber cement film as used herein means only one single layer having a thickness of between about 0.01 mm and about 0.9 mm that is applied onto the felt transport belt by the sieve from a vat of the Hatschek process.
• a fiber cement film as used herein means a superposition of two or more single layers, each having a thickness of between about 0.01 mm and about 0.9 mm, which are applied onto the felt transport belt by the sieve from a vat of the Hatschek process.
• hydrophobized or “hydrophobated” as used interchangeably herein refer to (fiber cement) products or fiber cement (film) layers, which have been treated before, during or after its production, with a hydrophobizing or hydrophobating agent.
• a “hydrophobized fiber cement product” or a “hydrophobized fiber cement sheet” as used herein will comprise at least one top fiber cement layer, which is treated with a hydrophobizing or hydrophobating agent.
• mass-coloured when referring to a fiber cement product has the meaning that at least part of the, and preferably the entire, internal structure of that fiber cement product comprises at least one, i.e. one or more, pigment(s).
• inter (fiber cement) structure means “internal (fiber cement) structure”, “inner (fiber cement) structure”, “internal (fiber cement) mass” or “inner (fiber cement) mass” as referred to interchangeably herein are used to indicate the fiber cement material present in a fiber cement product, which material is not visible with the eye when looking at the product from the outside.
• external (fiber cement) structure or “external (fiber cement) surface” as referred to interchangeably herein are used to indicate the fiber cement material which is exposed and visible on the outside of a fiber cement product.
• a “transparent pigment” as used herein is meant to indicate a pigment of which the pigment particles have the property of transmitting visible light.
• a “transparent pigment” as used herein is a pigment, of which the majority of pigment particles are smaller than the wave length of visible light.
• a “transparent pigment” as used herein is meant to indicate a pigment of which the pigment particles have the property of transmitting visible light.
• a “transparent pigment” as used herein is a pigment, of which the majority of pigment particles are smaller than the wave length of visible light.
• an “opaque pigment” as used herein is meant to indicate a pigment of which the pigment particles do not have the property of transmitting visible light.
• an “opaque pigment” as used herein is a pigment of which the majority of pigment particles are greater than the wave length of visible light.
• a “semi-opaque pigment” (also referred to in the art as a semi-transparent pigment) as used herein is meant to indicate a pigment of which only a certain but significant percentage of pigment particles have the property of transmitting visible light.
• a “semi-opaque pigment” as used herein is a pigment of which a certain but significant percentage of pigment particles are greater than the wave length of visible light and of which the remaining percentage of pigment particles are smaller than the wave length of visible light.
• pigment refers to a dry insoluble substance, usually pulverized, which when suspended in a liquid vehicle becomes a paint, ink, etc.
• Pigments typically consist of tiny solid particles that are used to enhance the appearance by providing color and/or to improve the physical (functional) properties of the paint or ink.
• Pigments used to provide color generally range from 0.2 to 0.4 microns in diameter.
• Functional pigments are typically 2-4 microns in diameter, but they may be as large as 50 microns.
• Prime pigment refers to any pigment (as defined herein), which is capable of providing whiteness and/or color to a substance while also contributing significantly to the hiding power of said substance. Prime pigments can be subdivided in white pigments and color pigments.
• white pigment as referred to herein means a prime pigment, capable of scattering light and providing whiteness and hiding in flat or glossy paint or ink.
• White inorganic pigments include but are not limited to antimony pigments including Antimony White: Sb 2 0 3 ; lead pigments (toxic) including White Lead (PbC0 3 ) 2 -Pb(0H) 2 ; titanium pigments including Titanium White: titanium (IV) oxide Ti0 2 and ; zinc pigments including Zinc White: Zinc Oxide (ZnO).
• color pigment as referred to herein means a prime pigment, capable of selectively absorbing light and providing color to a paint or ink. There are two main types of color pigments: organic pigments, which include the brighter colors but are not highly durable in exterior use and inorganic pigments, which are not as bright as organic colors but are the most durable exterior pigments.
• inorganic pigment refers to naturally occurring mineral coloring compounds typically consisting of metallic salts. Inorganic pigments are usually oxides or sulphides of one or more metals.
• Inorganic pigments include for instance but are not limited to:
• Blue inorganic pigments o aluminum pigments, including ultramarine: a complex naturally occurring pigment of sulfur- containing sodio-silicate ( a 8 -ioAl Si 6 S - ); o cobalt pigments, including Cobalt Blue and Cerulean Blue:cobalt(ll) stannate; o copper pigments, including Egyptian Blue: a synthetic pigment of calcium copper silicate (CaCuSi 4 Oio) and Han Blue BaCuSi4O10; and o iron pigments, including Prussian Blue: a synthetic pigment of ferric hexacya noferrate
• Green inorganic pigments o cadmium pigments including Viridian: a dark green pigment of hydrated chromium(lll) oxide (Cr 2 0 3 ) and Cadmium Green: a light green pigment consisting of a mixture of Cromium Yellow (CrS) and Viridian (Cr 2 0 3 ); o chromium pigments, including Chrome Green; copper pigments, including Paris Green: copper(ll) acetoarsenite (Cu(C 2 H 3 0 2 ) 2 -3Cu(As0 2 ) 2 ) and Scheele's Green (also called Schloss Green): copper arsenite CuHAs0 3;
• Yellow inorganic pigments o arsenic pigments including Orpiment natural monoclinic arsenic sulfide (As S 3 ); o cadmium pigments including Cadmium Yellow:cadmium sulfide (CdS); o chromium pigments including Chrome Yellow: natural pigment of iead(ll) chromate (PbCr0 4 ); o cobalt pigments including Aureolin (also called Cobalt Yellow): Potassium cobaltinitrite (Na 3 Co(N0 2 ) 6: o iron pigments including Yellow Ochre: a naturally occurring clay of hydrated iron oxide
• Orange inorganic pigments o cadmium pigments including Cadmium Orange: an intermediate between cadmium red and cadmium yellow: cadmium sulfoselenide; o chromium pigments including Chrome Orange: a naturally occurring pigment mixture composed of lead(ll) chromate and lead(ll) oxide. (PbCr0 4 + PbO)
• Red inorganic pigments o cadmium pigments including Cadmium Red: cadmium selenide (CdSe); o iron oxide pigments including Sanguine, Caput Mortuum, Oxide Red, Red Ochre: anhydrous Fe 2 0 3, Burnt Sienna: a pigment produced by heating Raw Sienna, Venetian Red; o lead pigments (toxic) including Red Lead: lead tetroxide, Pb 3 0 4; o mercury pigments (toxic) including Vermilion: Synthetic and natural pigment: Occurs naturally in mineral cinnabar; Mercuric sulfide (HgS);
• Brown inorganic pigments clay earth pigments including Raw Umber: A natural clay pigment consisting of iron oxide, manganese oxide and aluminum oxide: Fe 2 0 3 + Mn0 2 + nH 2 0 + Si + AI0 3 ; Raw Sienna: a naturally occurring yellow-brown pigment from limonite clay;
• Black inorganic pigments o Carbon pigments including Carbon Black, Ivory Black, Vine Black, Lamp Black; o Iron Pigments including Fe 3 0 4 ; o Titanium pigments: Titanium Black;
• Gray inorganic pigments o Payne's gray a mixture of Ultramarine and black or of Ultramarine and Sienna;
• organic pigment refers to synthetic organic coloring compounds, which are carbon based molecules manufactured from petroleum compounds, acids, and other chemicals, usually under intense heat or pressure.
• Organic pigments include for instance but are not limited to:
• Yellow Lakes which are transparent pigments used as a yellow to cover other inks but not hide them, Tartrazine Yellow Lake (also called FD&C Yellow No. 5 and used as a dyestuff in foods), Hansa Yellows, and Diarylide Yellows, which are the most common yellow pigments used in printing inks. Fluorescent Yellow is also used in some specialty applications. Organic Yellows are commonly used to replace Chrome Yellows; Orange organic pigments:
• the most common orange pigment is Diarylide Orange, a transparent yet not very fast-to-light pigment.
• Other assorted orange materials tend to be used where orange pigments are necessary, and include DNA Orange, Pyrazolone Orange, Fast Orange F2G, Benzimidazolone Orange HL, and Ethyl Lake Red C;
• Reds include Para Reds, Toluidine Red, ["Permanent Red “R”], Carmine F.B., Naphthol Reds and Rubines, Permanent Red FRC, Bordeaux FRR, Rubine Reds, Lithol Reds, BON Red, Lithol Rubine 4B, BON Maroon, Rhodamine 6G, Lake Red C, BON Arylamide Red, Quinacrinone Magentas, Copper Ferrocyanide Pink, Benzimidazolone Carmines and Reds, Azo Magenta G, Anthraquinone Scarlet, and Madder Lakes;
• Blues include Phthalocyanine Blues (the most commonly used group of organic blue pigments), PMTA Victoria Blue, Victoria Blue CFA, Ultramarine Blue, Indanthrene Blue, Alkali Blues, and Peacock Blue;
• Violets overlap slightly with some of the bluer reds (such as Benzimidazolone Bordeaux HF 3R (see Benzimidazolone Carmines and Reds), and also include such pigments as PMTA Rhodamine, PMTA Violet (also known as Methyl Violet), Dioxazine Violet (RL) Carbazole Violet, Crystal Violet, Dioxazine Violet B, and Thioindigoid Red;
• a common series of greens are the Phthalocyanine Greens as well as the PMTA Greens;
• Brown pigments include Diazo Brown and Benzimidazolone Brown HFR;
• extender pigment or “filler pigment” as used herein refers to any pigment (as defined herein) having a low refractive index or opacity and therefore not providing color or hiding power to a substance. Extender or filler pigments appear transparent in a paint or ink. Extender pigments have significant positive effects on various properties of the paint for example, as described further below, mica can improve the water resistance of a film due to its "platy" particle shape and tendency to orient itself in overlapping layers horizontal to the surface.
• Extender pigments or filler pigments for instance include but are not limited to Barium Sulphate, Calcium Carbonate, Magnesium Silicate , Mica, Kaolin (China Clay), Asbestine, Talc, Silica / Quartz, Alumina Hydrate, Kalunite, Pumice, Bentonite, Vermiculite, and Glass Beads.
• UV-curable refers to a composition that can polymerize upon application of UV irradiation. Typically, this at least implies the presence of photo-polymerizable monomers or oligomers, together with photoinitiators and/or photosensitizers.
• a “clear coat” or a “clear coating composition” as referred to herein is used to indicate a coating formulation or composition having the property of transmitting rays of light through its substance so that surfaces or objects, which are situated beyond or behind the coating, such as surfaces or objects coated by such transparent coating, are distinctly visible.
• Transparency when referring to a coating composition or a coating layer refers to the physical characteristic of allowing light to pass through the coating without being scattered. Transparency can be measured with any method known in the art. For instance, a haze meter measures the transparency, haze, see-through quality, and total transmittance of a coating, based on how much visible light is diffused or scattered when passing through the coating. Haze is measured with a wide-angle scattering test in which light is diffused in all directions which results in a loss of contrast. That percentage of light that when passing through deviates from the incident beam greater than 2.5 degrees on average is defined as haze.
• Total transmittance is the measure of the total incident light compared to the light that is actually transmitted (e.g. total transmittance). So, the incident light may be 100%, but because of absorption and reflection the total transmittance may only be 94%. The data gained from the haze meter can be transferred to a PC for further data processing to ensure a consistent product.
• polypropylene is intended to include any polymeric composition comprising propylene monomers, either as a homopolymer or copolymer with other polyolefins, dienes, or other monomers (such as ethylene, butylene, and the like).
• the term is also intended to encompass any different configuration and arrangement of the constituent monomers (such as syndiotactic, isotactic, and the like).
• the term as applied to filaments, monofilaments, multifilaments or fibers herein is intended to encompass endless stretches, actual long strands, threads, and the like, of polypropylene homopolymer or copolymer.
• slip-resistant is intended to refer to the surface of a material provided with an additional means for increasing the slip resistance and thereby increasing safety of those walking on roofs, or on any surfaces, on which the slip resistance material is installed.
• surface texture refers to the result of a process of embossing and are intended to refer to the result of an impression produced by pressure or printing and the process of making that impression over a receiving material or surface, and are thus intended to be interchangeable.
• the present invention provides novel textured composite building products, which are mechanically strong and highly resistant to humidity, cracks and wearing, even under harsh and adverse weather conditions. More particularly, the embossed pattern on the building products of the present invention forms a surface texture, which is characterized by outwardly extending projections, that are spread, scattered, dispersed and/or punctuated over at least one of the exposed surfaces of the product. In between the extending projections, the textured surface comprises a plurality of depressions.
• the projections of the textured surface of the building products of the present invention advantageously provide an improved slip resistance.
• the embossed pattern on the exposed surface of the building products provides an enhance friction surface thereby increasing the safety of the people walking onto this surface (e.g. on the surface of a decking element, a flooring element or a roofing element).
• the inventors have furthermore surprisingly observed that the depressions forming part of the textured surface of the building products of the present invention collectively form a network of channels and paths through which water, for instance coming from rain or snow, is more quickly drained (led away via the channels and paths) from the surface as compared to non-textured flat surfaces.
• the textured surface of the building products of the present invention inherently provides a novel and inventive way of rapidly relieving the exposed surfaces of building products from an excess of moisture and/or water. This advantage is even increased when the textured surface is treated with a hydrophobation agent.
• moisture is removed in a more efficient manner provides very important advantages to the products of the present invention, namely the protection against efflorescence, algae and/or moss growth.
• dirt particles falling on the surface are transported away together with the water flow through the network of channels and paths formed by the depressions present in the textured surface. Accordingly, dust and dirt particles do not have the chance to precipitate and stick on the surface itself.
• the products of the present invention are mass-coloured composite building products.
• the surface of these products beautifully displays the inner texture and colour of the core materials. This provides the products with a natural yet modern look and additionally provides for the esthetical advantage that any defects or damages occurring during the life-time of the products will be less visible compared to coated products, the latter of which are typically not coloured in the mass.
• the present invention provides fiber cement products, which are both technically (highly weather- and humidity-resistant as well as wearproof with good mechanical strength and impact resistance) and esthetically (intense though natural appearing colour and no colour change upon damage) improved.
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions characterized in that: the distance x (as measured perpendicularly to plane X of the building element) between the highest point of a projection and the lowest point of a depression is between 400 pm and 2000 pm and the total surface area of said irregularly textured surface is increased by 0,1% to 15% as compared to a non-textured surface area of the same material and with the same dimensions as the irregularly textured surface.
• the composite building material is a flat, panel-like, or sheet-like building element, such as a slate, a siding, a plank, a fagade panel, or a tile.
• the building element has a main front surface, which is partially or totally textured, and a main back surface, which can be textured on non-textured.
• plane X of the building element corresponds to the plane parallel to the front and back surface of said building element.
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions characterized in that the distance d (as measured perpendicularly to the plane X of the building element) between the highest point of a projection and the lowest point of a depression is between 500 pm and 1000 pm, preferably between 600 pm and 800 pm.
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions characterized in that the total surface area of said irregularly textured surface is increased by 1% to 0,5% as compared to a non-textured surface area of the same material and with the same dimensions as the irregularly textured surface.
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions characterized in that the total surface area of said irregularly textured surface is increased by 1% to 5% as compared to a non-textured surface area of the same material and with the same dimensions as the irregularly textured surface.
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions characterized in that at least a part and optionally all the projections are not sharp and have a rounded or flat top surface (i.e. the top surface is substantially parallel to the plane X of the building element).
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions characterized in that at least a part of the depressions has sharp edges (i.e. about perpendicularto the plane X of the building element).
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions, characterized in that: the distance y (as measured perpendicularly to the plane X of the building element) between the highest point of a projection and a reference base plane Y has a value between 100 pm and 600 pm; the distance z (as measured perpendicularly to the plane X of the building element) between the lowest point of a depression and a reference base plane Y has a value between 100 pm and 600 pm; wherein said reference base plane Y is positioned parallel to the plane X of the building element and cross-sections said projections and depressions in the middle of the average distance d between all projections and all depressions on said textured surface (as measured perpendicularly to the plane X of the building element).
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions, characterized in that: the distance y (as measured perpendicularly to the plane X of the building element) between the highest point of a projection and a reference base plane Y has a value between 200 pm and 400 pm; the distance z (as measured perpendicularly to the plane X of the building element) between the lowest point of a depression and a reference base plane Y has a value between 200 pm and 400 pm; wherein said reference base plane Y is positioned parallel to the plane X of the building element and cross-sections said projections and depressions in the middle of the average distance d between all projections and all depressions on said textured surface (as measured perpendicularly to the plane X of the building element).
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions, wherein the total cross-sectional area formed by a cross-section of the projections of the textured surface and a plane Z is between 200 and 800mm 2 / dm 2 of textured surface, wherein plane Z is positioned parallel to plane X of the building element and cross-sections the projections at 3/4 of the average distance d between all projections and all depressions on said textured surface (wherein the average distance d is the average of distances as measured perpendicularly to the plane X of the building element).
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions, wherein the total volume of the projections tops formed above the cross-section of these projections of the textured surface and a plane Z is between 50 and 150mm 3 / dm 2 of textured surface, wherein plane Z is positioned parallel to plane X of the building element and cross-sections the projections at 3/4 of the average distance d between all projections and all depressions on said textured surface (wherein the average distance d is the average of distances as measured perpendicularly to the plane X of the building element).
• Figure 4 a drawing of a cross-section of a textured surface is shown, indicating the following parameters:
• microscopy such as SEM microsopy, 3D profilometers etc.
• the present invention provides a composite building material, having at least one irregularly textured surface comprising a plurality of projections and depressions, characterized in that the surface comprises between 50 and 250 projections per dm 2 . In further particular embodiments, the textured surface comprises between 100 and 200 projections per dm 2 .
• the present invention provides a composite building material, having at least one irregularly textured surface, wherein said surface is characterized by a developed interfacial area surface Sdr of between 0,001 and 0,050.
• the developed interfacial area surface Sdr is defined as the ratio between the area of the irregularly textured surface and the area of a flat two-dimensional projection of the irregularly textured surface. This ratio is also known in the art as the "complexity" of the surface. In the ISO 25178 standard, Sdr is calculated by the following formula:
• the present invention provides a composite building material, having at least one textured surface comprising a plurality of projections and depressions, wherein said textured surface is hydrophobated.
• the present invention provides a composite building material, having at least one textured surface comprising a plurality of projections and depressions, wherein said plurality of projections and depressions have an irregular non-geometric shape.
• the present invention provides a composite building material, which is a cement-bonded composite material or a gypsum-bonded composite material.
• the composite building material is chosen from the group consisting of fiber cementitious material, calcium silicate-based material or gypsum-based material.
• the present invention provides a composite building material, which is a facade element, a roofing element, a flooring element or a decking element.
• the present invention provides a composite building material, which is a building sheet or a building panel.
• fiber cement products are to be understood as cementitious products comprising cement and synthetic (and optionally natural) fibers.
• the fiber cement products are made out of fiber cement slurry, which is formed in a so-called “green” fiber cement product, and then cured.
• the fiber cement slurry typically comprises water, process or reinforcing fibers which are synthetic organic fibers (and optionally also natural organic fibers, such as cellulose), cement (e.g. Portland cement), limestone, chalk, quick lime, slaked or hydrated lime, ground sand, silica sand flour, quartz flour, amorphous silica, condensed silica fume, microsilica, kaolin, metakaolin, wollastonite, mica, perlite, vermiculite, aluminum hydroxide (ATH), pigments, anti-foaming agents, flocculants, and/or other additives.
• synthetic organic fibers e.g. Portland cement
• limestone e.g. Portland cement
• limestone limestone
• chalk quick lime
• slaked or hydrated lime ground sand
• silica sand flour e.g.
• quartz flour e.g. amorphous silica
• condensed silica fume e.g. kaolin, metakaolin,
• the fiber cement products of the present invention at least further comprise synthetic fibers.
• the fiber cement products of the present invention comprise from about 0.1 to about 5 weight %, such as particularly from about 0.5 to about 4 weight % of synthetic fibers, such as more particularly between about 1 to 3 weight % of synthetic fibers, such as most particularly about 2 weight % of synthetic fibers with respect to the total weight of the fiber cement product.
• the synthetic fibers are selected from the group consisting of polypropylene fibers, polyvinylalcohol fibers, polyacrylonitrile fibers, polyethyelene, polyamide fibers, polyester fibers, aramide fibers and carbon fibers.
• the synthetic fibers in the fiber cement products of the present invention are polypropylene fibers and/or polyvinylalcohol (PVA) fibers.
• the synthetic fibers are polypropylene fibers having a thickness of about 70 dtex.
• the synthetic fibers are milled polypropylene fibers.
• the synthetic fibers are milled polypropylene fibers having an average length of about 1 mm to about 2 mm.
• natural fibers such as cellulose fibers may in addition be added to the fiber cement formulations of the present invention.
• the fiber cement products of the present invention may comprise from about 2 to about 5 weight %, such as particularly about 2 to about 4 weight % of cellulose fibers, such as more particularly about 3 weight % of cellulose fibers with respect to the total weight of the fiber cement product.
• These cellulose fibers may for example be Kraft softwood cellulose fibers, such as bleached Kraft softwood cellulose fibers.
• additional fibers may be added to the cement formulations and may be selected from the group consisting of glass fibers, rockwool fibers, slag wool fibers, wollastonite fibers, ceramic fibers and the like.
• the fiber cement products of the present invention may additionally comprise fibrils fibrids, such as for example but not limited to, polyolefinic fibrils fibrids % in a weight % of about 0.1 to 3, such as "synthetic wood pulp".
• the fiber cement products according to the invention optionally comprise further components.
• these further components in the fiber cement products of the present invention may be selected from the group consisting of water, sand, silica sand flour, condensed silica fume, microsilica, fly-ashes, ground quartz, the ground rock, clays, pigments, kaolin, metakaolin, blast furnace slag, carbonates, puzzolanas, aluminium hydroxide, wollastonite, mica, perlite, calcium carbonate, and other additives (e.g. colouring additives) etc.
• the total quantity of such further components is preferably lower than 70 weight % compared to the total initial dry weight of the composition.
• Further additives that may be present in the fiber cement products of the present invention may be selected from the group consisting of dispersants, plasticizers, antifoam agents and flocculants.
• the total quantity of additives is preferably between about 0.1 and about 2 weight % compared to the total initial dry weight of the composition.
• the fiber cement products of the invention have a thickness of between about 5 mm and about 25 mm, in particular between about 5 mm and about 20 mm.
• the fiber cement products of the invention have a length of between about 2 m and about 6 m, in particular between about 2 m and about 4 m, more in particular of about 2.40m or of about 3.50 m.
• the fiber cement products of the invention have a width of between about 1 m and about 4 m, more in particular of about 1.20 m.
• the fiber cement products of the present invention can be coated with a coating, which can be a coloured coating or a clear coating (as defined herein).
• the coloured coating can be a conventional acrylic coating.
• the coating is a conventional clear coating (i.e. not radiation-curable).
• Suitable conventional clear coatings are those with binders obtained by aqueous free radical or ionic emulsion polymerization.
• Acrylic and/or methacrylic (co)polymers are particularly preferred as binders of the conventional clear coatings. These acrylic and/or methacrylic (co)polymers are usually prepared by aqueous radically initiated emulsion polymerization of esters of acrylic acid and/or methacrylic acid with C1-C12 alkanols as well as a minor amount of acrylic and/or methacrylic acid as monomers.
• esters of acrylic and methacrylic acid with C1-C8 alkanols ethyl acrylate, n-butyl acrylate, ethylhexyl acrylate and methylmethacrylate are particularly preferred.
• the emulsion polymerization requires the use of surfactants as stabilizers. Non-ionic surfactants are preferred. Alcohol ethoxylates are particularly preferred. Conventional coatings with a hydroxyl number (measured according to ISO 4629) of at least 1 are preferred. Hydroxyl numbers of at least 1,5 are particularly preferred.
• the minimum film forming temperature during the drying of the conventional coating is below 60°C.
• the conventional clear coating composition generally comprises, besides the polymeric binders and pigments, also usual auxiliaries, e.g. fillers, wetting agents, viscosity modifiers, dispersants, defoamers, preservatives and hydrophobisizers, biocides, fibers and other usual constituents.
• auxiliaries e.g. fillers, wetting agents, viscosity modifiers, dispersants, defoamers, preservatives and hydrophobisizers, biocides, fibers and other usual constituents.
• suitable fillers are aluminosilicates, silicates, alkaline earth metal carbonates, preferably calcium carbonate in the form of calcite or lime, dolomite, and also aluminum silicates or magnesium silicates, e.g. talc.
• the solids content of suitable conventional clear coatings is generally in the range from 20 to 60% by weight.
• the conventional clear coating compositions comprise as liquid component essentially water and, if desired, an organic liquid miscible with water, for example an alcohol.
• the conventional coating compositions are applied at a wet coating weight in the range from 50 to 500 g/m 2 , in particular from 70 to 300 g/m 2 , in a known manner, for example by spraying, troweling, curtain coating, knife application, brushing, rolling or pouring onto the cement bonded board, or by a combination of one or more applications.
• the clear coating is a radiation-curable clear coating.
• Radiation- curable coatings are known in the art and comprise at least one polymer A having ethylenically unsaturated double bonds, which is radiation-curable.
• Possible polymers A for the radiation-curable compositions are in principle any polymers having ethylenically unsaturated double bonds which can undergo radical-initiated polymerization on exposure to UV radiation or electron beam radiation. Care should be taken here that the content of ethylenically unsaturated double bonds in the polymer is sufficient to ensure effective crosslinking.
• the content of ethylenically unsaturated double bonds in A is generally in the range from 0,01 to 1,0 mol/100 g of A, more preferably from 0,05 to 0,8 mol/100 g of A and most preferably from 0,1 to 0,6 mol/100 g of A.
• Suitable polymers A are polyurethane derivatives which contain ethylenically unsaturated double bonds, such as polyurethane acrylates.
• the radiation-curable composition further comprises at least one chemically and radiation crosslinkable polymer B.
• Suitable polymers B are free isocyanate-bearing polyurethanes having ethylenically unsaturated double bonds. Polyurethane acrylates with free isocyanate groups are preferred.
• the reaction of the free isocyanate groups with moisture present in the air takes place at room temperature, in particular, in areas not exposed to radiation and hence not completely cured (back side, edges, cavities formed in the radiation-curable coating, ).
• the free isocyanate content of B measured according to DIN EN ISO 11 909, ranges usually from 5 to 20% by weight.
• the free isocyanate content of B is between 8 and 20% by weight and more preferably between 10 and 18 % by weight.
• the weight ratio of B /A is preferably in the range of 0,03/0,2.
• a weight ratio of B/A in the range of 0,05/0,1 is particularly preferred.
• the radiation-curable preparations may also contain a compound different from polymer A and polymer B and having a molecular weight of less than 800 g/mol and capable of polymerization by cationic or free-radical pathways. These compounds have generally at least one ethylenically unsaturated double bond and/or one epoxy group and a molecular weight being less than 800 g/mol. Such compounds generally serve to adjust to the desired working consistency of the radiation-curable preparations.
• the preparation contains no other diluents, such as water and/or inert organic solvents, or contains these only to a subordinate extent.
• Such compounds are therefore also termed reactive diluents.
• the proportion of reactive diluents based on the total amount of (A+B) and the reactive diluent in the radiation-curable preparation, is preferably in the range of 0 to 90% by weight, and most preferably in the range of from 5 to 50 % by weight.
• Preferred reactive diluents are the esterification products of di- or polyhydric alcohols with acrylic and/or methacrylic acid.
• Such compounds are generally termed polyacrylates or polyether acrylates.
• the radiation-curable compositions may also comprise polymers which have cationically polymerizable groups, in particular epoxy groups. These include copolymers of ethylenically unsaturated monomers, the copolymers containing, as comonomers, ethylenically unsaturated glycidyl ethers and/or glycidyl esters of ethylenically unsaturated carboxylic acids.
• compositions may comprise, instead of or together with the cationically polymerizable polymers, a low-molecular-weight, cationically polymerizable compound, for example a di- or polyglycidyl ether of a low-molecular-weight di- or polyol or the di- or polyester of a low-molecular weight di- or polycarboxylic acid.
• the radiation-curable compositions comprise usual auxiliaries, such as thickeners, flow control agents, defoamers, UV stabilizers, emulsifiers, surface tension reducers and/or protective colloids.
• auxiliaries are well known to the person skilled in the coatings technology.
• Silicones particularly polyether modified polydimethylsiloxane copolymers, may be used as surface additives to provide good substrate wetting and good anti-crater performance by reduction of surface tension of the coatings.
• Suitable stabilizers encompass typical UV absorbers, such as oxanilides, triazines, benzotriazoles (obtainable as TinuvinTM grades from Ciba Geigy) and benzophenones.
• HALS compounds 2,2,6,6-tetramethylpiperidine and 2,6-di-tert-butylpiperidine
• Stabilizers are usually used in amounts of from 0,1 to 5,0% by weight and preferably from 0,3 to 2,5% by weight, based on the polymerizable components present in the preparation.
• the preparations to be used comprise at least one photoinitiator.
• photoinitiators for free-radical curing mechanisms polymerization of ethylenically unsaturated double bonds
• photoinitiators for cationic curing mechanisms cationic polymerization of ethylenically unsaturated double bonds or polymerization of compounds containing epoxy groups.
• Photoinitiators are not needed for electron beam curable compositions.
• Suitable photoinitiators for free-radical photopolymerization i.e. polymerization of ethylenically unsaturated double bonds
• benzophenone and benzophenone derivatives such as 4- phenylbenzophenone and 4-chlorobenzophenone, Michler's ketone, a nth rone, acetophenone derivatives, such as 1-benzoylcyclohexan-l-ol, 2-hydroxy-2,2-dimethylacetophenone and 2,2- dimethoxy-2-phenylacetophenone
• benzoin and benzoin ethers such as methyl benzoin ether, ethyl benzoin ether and butyl benzoin ether
• benzil ketals such as benzil dimethyl ketal, 2-methyl-l-[4- (methylthio) phenyl]-2-morpholinopropan-l-one, anthraquinone and its derivatives, such as .beta.-
• Suitable photoinitiators for cationic photopolymerization i.e. the polymerization of vinyl compounds or compounds containing epoxy groups
• aryl diazonium salts such as 4-methoxybenzenediazonium hexafluorophosphate, benzenediazonium tetrafluoroborate and toluenediazonium tetrafluoroarsenate
• aryliodonium salts such as diphenyliodonium hexafluoroarsenate
• arylsulfonium salts such as triphenylsulfonium hexafluorophosphate, benzene- and toluenesulfonium hexafluorophosphate and bis[4-diphenylsulfoniophenyl] sulfide bishexafluorophosphate
• disulfones such as diphenyl disulfone and phenyl-4-tolyl disulfone, di
• the abovementioned photoinitiators are used, in amounts from 0,05 to 20% by weight, preferably from 0,1 to 10% by weight and in particular from 0,1 to 5% by weight, based on the polymerizable components of the radiation-curable composition.
• the clear coating suitable for application on the textured surface of the fiber cement products of the present invention comprises one or more pigments.
• the radiation-curable compositions are applied in a known manner, e.g. by spraying, troweling, knife application, brushing, rolling or pouring onto the cement bonded board. It is also conceivable that the preparation may be applied to the cement board by hot-melt processes or by powder-coating processes.
• the radiation-curable composition is preferably applied by roller-coating.
• the radiation- curable composition is usually applied to obtain a dry thickness in the range from 10 to 100 Pm, preferably from 50 to 80 Pm. The application may take place either at room temperature or at elevated temperature, but preferably not above 100 °C.
• the liquid coated surface is roll-covered with a radiation permeable film before applying radiation. Care is taken to have an intimate contact between the liquid coated panels and the controlled surface layer of the film, in order to remove entrapped bubbles and air pockets between the overlying film and the panel by the roller.
• This film provides protection against the radical chain-breaking reaction of oxygen, and avoids the use of inert gas atmosphere in the case of electron beam curing.
• this covering film has a controlled gloss surface with a predetermined surface finish on the side in contact with the liquid coated panel surface.
• Suitable radiation permeable films are thin plastic films of polyester or polyolefins.
• the controlled surface gloss on the radiation permeable film can be obtained in various ways, such as embossing, printing, coating, etching or by the use of matting additives.
• the radiation permeable film with its regularly distributed surface micro- roughness can possibly be texturized, e.g. allowing labeling.
• the radiation curable coating may be cured by exposure to UV radiation of wavelength generally from 200 to 600 nm.
• UV sources are high and medium pressure mercury, iron, gallium or lead vapor lamps.
• Medium pressure mercury vapor lamps are particularly preferred, e.g. the CK or CK1 sources from the company 1ST (Institut fur Strahlungstechnologie).
• the radiation dose usually sufficient for crosslinking is in the range from 80 to 3000 mJ/cm2.
• Any solvent present, in particular water, is dried out before the curing in a separate drying step preceding curing, for example by heating to temperatures in the range from 40 to 80 °C, or by exposure to IR radiation.
• irradiation is performed with high-energy electrons (usually from 100 to 350 keV, by applying a high voltage to tungsten filaments inside a vacuum chamber), and the actual curing step takes place in an inert, oxygen-free atmosphere. After irradiation, the covering film is removed by peeling it off.
• high-energy electrons usually from 100 to 350 keV, by applying a high voltage to tungsten filaments inside a vacuum chamber
• the present invention provides a method for producing a composite building material having at least one textured surface comprising a plurality of projections and depressions, wherein said method comprises the steps of: a) Providing a composite building material, and b) Texturing at least one surface of said composite building material by applying a mechanical pressure.
• the composite building material is a cement-bonded composite material or a gypsum-bonded composite material.
• the composite building material is chosen from the group consisting of fiber cementitious material, calcium silicate-based material or gypsum-based material.
• the present invention provides a method for producing a composite building material having at least one textured surface comprising a plurality of projections and depressions, wherein said method comprises the steps of: a) Providing a fiber cement slurry, b) Producing a green fiber cement product, c) Texturing at least one surface of said composite building material by applying a mechanical pressure, and d) Curing said fiber cement product so as to obtain a composite building material having at least one textured surface.
• the methods of the present invention further comprise the step of applying a hydrophobation agent to the textured surface.
• the methods of the present invention further comprise the step of applying a coating to the textured surface.
• the methods of the present invention further comprise the step of applying a mixture of a coating and a hydrophobation agent to the textured surface.
• a fiber cement slurry can be prepared by using one or more sources of at least cement, water and fibers in the amounts as previously disclosed herein.
• these one or more sources of at least cement, water and pigmented synthetic fibers are operatively connected to a continuous mixing device constructed so as to form a cementitious fiber cement slurry.
• the manufacture of the fiber cement products can be executed according to any known procedure.
• the step b) of providing a fiber cement product can be performed according to any method known in the art for preparing fiber cement products, which products at least comprise cement, water and synthetic fibers.
• the process most widely used for manufacturing fiber cement products is the Hatschek process, which is performed using a modified sieve cylinder paper making machine.
• Other manufacturing processes that can be used include the Magnani process, injection, flow-on, extrusion and others.
• the fiber cement products of the present invention are provided by using the Hatschek process.
• the "green" or uncured fiber cement product is optionally post-compressed usually at pressures in the range from about 22 to about 30 MPa to obtain the desired density.
• the processes according to the present invention may further comprise the step of cutting the fiber cement products to a predetermined length to form a fiber cement product.
• Cutting the fiber cement products to a predetermined length can be done by any technique known in the art, such as but not limited to water jet cutting, air jet cutting or the like.
• the fiber cement products can be cut to any desirable length and width but preferably to the dimensions as disclosed previously herein for the products of the present invention.
• the pale-colored fiber cement products of the present invention can be cut into specific dimensions so as to form fiber cement boards, panels, plates, sidings, planks, tiles etc.
• processes of the present invention may further comprise additional steps of processing the produced fiber cement products.
• the fiber cement slurry and/or the fiber cement products may undergo various intermediate treatments, such as but not limited to treatment with one or more hydrophobic agents, treatment with one or more flocculants, additional or intermediate pressing steps, etc.
• the border strips can optionally be recycled through immediate mixing with the recycled water and directing the mixture to the mixing system again.
• step c) of the methods of the present invention i.e. texturing
• step c) of the methods of the present invention can be done by treating at least one surface of said composite building material by brushing, sand blasting abrasive blasting or any other suitable texturing step at a suitable pressure.
• step d) of the methods of the present invention the obtained fiber cement products are cured.
• fiber cement products can be allowed to cure over a time in the environment in which they are formed, or alternatively can be subjected to a thermal cure (e.g. by autoclaving or the like).
• the fiber cement products of the present invention are air-cured.
• This air curing step involves curing the green fiber cement products under ambient conditions for about 2 to 4 weeks, such as for about 3 weeks. It has been found by the present inventors that air-cured fiber cement products as produced according to the methods as disclosed herein perform particularly well, especially having regard to their mechanical characteristics, such as impact resistance and mechanical strength. This will become clear from the Examples as further described herein.
• the "green" fiber cement products may be first pre-cured to the air, after which the pre-cured product is further air-cured until it has its final strength to give the product its final properties.
• the processes may further comprise the step of thermally drying the obtained fiber cement products.
• the fiber cement product being a panel, sheet or plate, etc. may still comprise a significant weight of water, present as humidity. This may be up to 10 even 15 %w, expressed per weight of the dry product.
• the weight of dry product is defined as the weight of the product when the product is subjected to drying at 105°C in a ventilated furnace, until a constant weight is obtained.
• the fiber cement product is dried. Such drying is done preferably by air drying and is terminated when the weight percentage of humidity of the fiber cement product is less than or equal to 8 weight %, even less than or equal to 6 weight %, expressed per weight of dry product, and most preferably between 4 weight % and 6 weight %, inclusive.
• the present invention provides uses of the fiber cement products according to the present invention as building materials.
• the present invention provides uses of the fiber cement products according to the present invention as an outer surface to walls, applied internally or externally, e.g. as fagade plate, siding, etc.
• the fiber cement products according to the present invention can be used for decking or flooring applications, fencing applications and/or covering applications.
• the fiber cement products according to the present invention can be used for roofing applications, such as slates.
• the present invention provides uses of the building material according to the present invention as a facade element, a roofing element, a flooring element or a decking element.
• the present invention provides fiber cement products obtainable by any of the methods according to the present invention.
• the invention will now be further illustrated in detail with reference to the following Examples.
• the composite building products of the present invention are characterized by an attractive esthetic appearance because of their textured aspect and their original surface pattern as achieved through the presence of the plurality of projections and depressions (as shown in Figures 1 to 4).
• the present invention provides fiber cement products, which are also technically superbe because of theirweather- and humidity-resistance and good mechanical strength and impact resistance.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Structural Engineering (AREA)
• Civil Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Ceramic Engineering (AREA)
• Mechanical Engineering (AREA)
• Finishing Walls (AREA)
• Laminated Bodies (AREA)
• Floor Finish (AREA)

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• 2020
  • 2020-10-30 WO PCT/EP2020/080520 patent/WO2021089428A1/en active Application Filing
  • 2020-10-30 GB GB2206137.8A patent/GB2603725B/en active Active
  • 2020-10-30 DE DE212020000765.9U patent/DE212020000765U1/de active Active
  • 2020-10-30 AT ATGM9013/2020U patent/AT17726U1/de unknown
• 2022
  • 2022-07-06 DK DKBA202200055U patent/DK202200055Y3/da active IP Right Grant

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