WO2023163666A1 - Procédé de formation d'une feuille composite de fibrociment présentant une surface lisse et feuille composite de fibrociment obtenue à partir dudit procédé - Google Patents
Procédé de formation d'une feuille composite de fibrociment présentant une surface lisse et feuille composite de fibrociment obtenue à partir dudit procédé Download PDFInfo
- Publication number
- WO2023163666A1 WO2023163666A1 PCT/TH2022/000031 TH2022000031W WO2023163666A1 WO 2023163666 A1 WO2023163666 A1 WO 2023163666A1 TH 2022000031 W TH2022000031 W TH 2022000031W WO 2023163666 A1 WO2023163666 A1 WO 2023163666A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- fiber
- amount
- composite sheet
- forming
- cement composite
- Prior art date
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- 239000004568 cement Substances 0.000 title claims abstract description 201
- 239000002131 composite material Substances 0.000 title claims abstract description 181
- 238000000034 method Methods 0.000 title claims abstract description 98
- 230000008569 process Effects 0.000 title claims abstract description 89
- 239000000203 mixture Substances 0.000 claims abstract description 179
- 239000002002 slurry Substances 0.000 claims abstract description 151
- 239000000463 material Substances 0.000 claims abstract description 138
- 239000010410 layer Substances 0.000 claims abstract description 120
- 239000002344 surface layer Substances 0.000 claims abstract description 76
- 239000011248 coating agent Substances 0.000 claims abstract description 55
- 238000000576 coating method Methods 0.000 claims abstract description 55
- 239000000835 fiber Substances 0.000 claims description 146
- 239000000654 additive Substances 0.000 claims description 36
- 230000000996 additive effect Effects 0.000 claims description 34
- 239000000945 filler Substances 0.000 claims description 27
- 238000002156 mixing Methods 0.000 claims description 22
- 239000003795 chemical substances by application Substances 0.000 claims description 17
- 230000001070 adhesive effect Effects 0.000 claims description 12
- 239000000853 adhesive Substances 0.000 claims description 10
- -1 luminescence Substances 0.000 claims description 10
- 239000000049 pigment Substances 0.000 claims description 10
- 239000002518 antifoaming agent Substances 0.000 claims description 9
- 239000004067 bulking agent Substances 0.000 claims description 9
- 239000003054 catalyst Substances 0.000 claims description 9
- 239000002270 dispersing agent Substances 0.000 claims description 9
- 239000003112 inhibitor Substances 0.000 claims description 9
- 238000004020 luminiscence type Methods 0.000 claims description 9
- 239000003755 preservative agent Substances 0.000 claims description 9
- 230000002335 preservative effect Effects 0.000 claims description 9
- 239000012744 reinforcing agent Substances 0.000 claims description 9
- 239000012748 slip agent Substances 0.000 claims description 9
- 238000004519 manufacturing process Methods 0.000 abstract description 6
- 239000000523 sample Substances 0.000 description 36
- 239000013068 control sample Substances 0.000 description 22
- 238000001723 curing Methods 0.000 description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 7
- 238000012360 testing method Methods 0.000 description 7
- 238000002360 preparation method Methods 0.000 description 6
- 239000000126 substance Substances 0.000 description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 6
- 238000010276 construction Methods 0.000 description 5
- 238000012986 modification Methods 0.000 description 5
- 230000004048 modification Effects 0.000 description 5
- 239000002023 wood Substances 0.000 description 5
- 239000011398 Portland cement Substances 0.000 description 3
- 229920001131 Pulp (paper) Polymers 0.000 description 3
- 230000006872 improvement Effects 0.000 description 3
- 238000011835 investigation Methods 0.000 description 3
- 239000004576 sand Substances 0.000 description 3
- 238000003860 storage Methods 0.000 description 3
- 241000278701 Acacia mangium Species 0.000 description 2
- 235000017631 Acacia mangium Nutrition 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 239000000123 paper Substances 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 238000004064 recycling Methods 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- 240000006409 Acacia auriculiformis Species 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- 244000166124 Eucalyptus globulus Species 0.000 description 1
- LSNNMFCWUKXFEE-UHFFFAOYSA-N Sulfurous acid Chemical compound OS(O)=O LSNNMFCWUKXFEE-UHFFFAOYSA-N 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 239000002956 ash Substances 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 230000009975 flexible effect Effects 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 239000011121 hardwood Substances 0.000 description 1
- 239000011396 hydraulic cement Substances 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 229920000609 methyl cellulose Polymers 0.000 description 1
- 239000001923 methylcellulose Substances 0.000 description 1
- 235000010981 methylcellulose Nutrition 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
- 239000010893 paper waste Substances 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000001179 sorption measurement Methods 0.000 description 1
- 230000032258 transport Effects 0.000 description 1
- YSGSDAIMSCVPHG-UHFFFAOYSA-N valyl-methionine Chemical compound CSCCC(C(O)=O)NC(=O)C(N)C(C)C YSGSDAIMSCVPHG-UHFFFAOYSA-N 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
- B28B1/522—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement for producing multi-layered articles
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- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
- B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
- B28B1/525—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement containing organic fibres, e.g. wood fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
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- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
- B28B1/527—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement by delivering the materials on a rotating drum, e.g. a sieve drum, from which the materials are picked up by a felt
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
- B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
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- B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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- C04B16/00—Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B16/02—Cellulosic materials
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- 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
- C04B28/04—Portland cements
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- C—CHEMISTRY; METALLURGY
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- C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
- C04B40/0028—Aspects relating to the mixing step of the mortar preparation
- C04B40/006—Aspects relating to the mixing step of the mortar preparation involving the elimination of excess water from the mixture
- C04B40/0064—Processes of the Magnini or Hatscheck type
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- 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
- E04C2/28—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 combinations of materials fully covered by groups E04C2/04 and E04C2/08
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- 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
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
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- B32B2255/00—Coating on the layer surface
- B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
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- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/044—Water-setting substance, e.g. concrete, plaster
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- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/06—Vegetal fibres
- B32B2262/062—Cellulose fibres, e.g. cotton
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- B32B2262/067—Wood fibres
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- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/22—Fibres of short length
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- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/54—Yield strength; Tensile strength
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- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/558—Impact strength, toughness
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2419/00—Buildings or parts thereof
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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
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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
- C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
- C04B2201/50—Mortars, concrete or artificial stone characterised by specific physical values for the mechanical strength
-
- 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
Definitions
- the present invention relates to the field of engineering, in particular, to a process for forming a fiber-cement composite sheet having smooth-surface and the fiber-cement composite sheet obtained from said process.
- Fibercement is an alternative composite material that can be used instead of a real wood. In other words, it is called a synthetic wood. It is made from mixing cementitious material, filler, siliceous material, additive, and fiber together and subjected to fabricate the fibercement (e.g. extrusion process, Hatschek process and the likes). The thickness, size, and appearance can be determined according to use.
- the fiber-cement is used in construction work in structures, fences, walls, rooves, including interiors of buildings. Properties of the composite material used in forming depend on the compositional ratio of the composition, production process, and layer structure of the fiber-cement, which affects the mechanical property of the material, strength, and durability of the product.
- Fiber-cement can be manufactured using Hatschek process.
- Hatschek process By this process, the compositions in slurry form are mixed in a mixing tank. Then, the slurry composition is conveyed into a vat having a sieve installed therein.
- a conveyor belt (for example, felt conveyor belt or similar) rolls through the sieve and forms a wet film from the slurry composition. The film layer is pressed to remove water by a roller installed above the sieve in order to release the film from the sieve onto the surface of the conveyor belt as a fibercement composite sheet.
- the conveyor belt conveys said fiber-cement to the roller for forming a fiber-cement composite sheet at the desired thickness. Then, the fiber-cement composite sheet is cured to set within a predetermined time.
- the fiber-cement composite sheet obtained from normal Hatschek process provides a strength which is suitable for construction work.
- the other preferred character of the fibercement composite sheet is a smooth-surface for the ease of further work such as painting, coating, decorating in order to obtain a clear pattern on the product surface, including printing or laminating work.
- special processes are needed, for example, high pressure pressing sanding, polishing or surface rubbing. These special processes reduce the thickness and strength of the product, and also increase the cost because of the extra steps or processes in the production.
- Patent publication WO 2002070218 Al disclosed a fiber reinforced cement (FRC) having improvement of a surface of a fiber-cement composite sheet by producing a coating material for surface properties, including smoothness.
- Said process comprises the step of: a) providing a slurry composition comprising cement, silica, fiber, and additive in the composition; b) feeding the slurry from a mixing machine into at least 1 vat, wherein each vat is connected to a sieve; c) forming the fiber-cement composite sheet on a roller using Hatschek process; and d) curing.
- Step c) further comprises a spattered layer before forming on the roller with another slurry composition having different composition in order to improve a surface property of the fiber-cement composite sheet.
- this document disclosed the forming of the fiber-cement composite sheet by Hatschek process and obtaining the fiber-cement composite sheet with adjusted surface condition
- the Hatschek process disclosed in this document only uses one slurry composition in the forming of fiber-cement composite sheet from the sieve then adding the spattered layer with another substance. This is different from the forming of material layer from two slurry compositions via separate sieves which gives different composition that causes different physical properties without the need of the spattered layer.
- said document does not aim to maintain the strength of the obtained fiber-cement composite sheet product and does not propose to use the fiber-cement composite sheet for saving an amount of coating material (e.g. color).
- Patent publication US 20180169895 Al disclosed a forming process of a fibercement composite sheet comprising the step of: a) providing a fiber-cement slurry composition containing filler and additive in a mixing tank; b) feeding the slurry composition from the mixing tank to at least 2 vats, each vat being connected to at least 2 sieves; c) forming at least 1 layer of fiber-cement on a drum from the slurry composition using Hatschek process; and d) taking the layer of the fiber-cement composite off the drum and curing until completely solid.
- Each vat has an input pipe and valve for controlling the level of the slurry composition from the mixing tank separately for ease of controlling the substance level in the vat.
- Canadian Journal of Civil Engineering (27(3), 543-552) disclosed the forming of a fiber-cement using an auger-type extruder which intended to study physical properties of the obtained fiber-cement.
- Said extrusion used slurry composition comprising cement, silica, methyl cellulose and either long fiber or short fiber.
- the study found that the forming of the fiber-cement having only short fiber provided the fiber-cement with smoother surface property than the forming of the fiber-cement having only long fiber.
- the forming of fiber-cement having only long fiber provided better strength property.
- the disclosed process in said document is the forming by a screwed extruder in which the screwed extruder extrudes the slurry composition via the screwed pressure inside the machine causing stress in the material which affects the strength of the internal structure of the obtained fiber-cement.
- the forming by screwed extruder differs from the layer forming process using Hatschek process because of different conditions. That is, the Hatschek process is the forming layer by layer which needs to consider the adhesive strength of each layer. It also needs to consider the volume ratio for forming each layer.
- this invention aims to develop a Hatschek process of forming fibercement composite sheet for forming a fiber-cement composite sheet having smooth-surface layer which saves the amount of coating material and still has a base layer for strength without any further production step.
- the present invention relates to a process of forming a fiber-cement composite sheet having smooth-surface which saves the amount of coating material used, where the fiber-cement composite sheet still has the same strength.
- the process comprises the steps of: a) providing at least two slurry compositions separately in at least two mixing tanks for forming the fiber-cement composite sheet comprising at least two composite layers, where
- the first slurry composition is used for forming a base layer of the fibercement composite sheet
- the first slurry composition in step a) comprises: a cement material in an amount from 1 to 10 % w/v; a siliceous material in an amount from 1 to 10 % w/v; a filler in an amount from 0.1 to 10 % w/v; a long fiber in an amount from 0.1 to 2 % w/v; and a medium up to 100 % w/v; and wherein the second slurry composition
- Figure 1 shows examples of a) fiber-cement composite sheet formed by a layer of one composite material, b) fiber-cement composite sheet formed by layers of two composite materials according to the exemplary embodiments of the invention, and c) fiber-cement composite sheet formed by layers of two composite materials with an intermediate layer according to the exemplary embodiments of the invention.
- Figure 2 shows a diameter, a length of the long fiber and short fiber used in the exemplary embodiments of the invention.
- Figure 3 shows a flow chart of process using two slurry compositions according to the exemplary embodiments of the invention (sample A-l, B-l to B-9, and C-l).
- Figure 4 shows a control sample 1, sample B-8, and sample C-l according to the exemplary embodiments of the invention.
- Figure 5 shows a surface of control sample 1 and sample B-8 according to the exemplary embodiments of the invention.
- Figure 6 shows a use of the fiber-cement composite sheet of control sample 1 and sample B-8 according to the exemplary embodiments of the invention.
- Figure 7 shows an example of the fiber-cement composite sheet containing an additive according to the exemplary embodiments of the invention, where a) contains the additive of pigment and b) contains the additive of adhesive property.
- the present invention relates to a process of forming a fiber-cement composite sheet having smooth-surface which saves the amount of coating material used, where the fiber-cement composite sheet still has the same strength.
- any tools, equipment, methods, or chemicals named herein mean tools, equipment, methods, or chemicals being used commonly by an ordinary person skilled in the art unless expressly stated that they are tools, equipment, methods, or chemicals specific only to this invention.
- coat refers to a coating material applied to the surface of fiber-cement composite sheet, where the coating material is selected from color, multiple color, clear coat, pattern, multiple color pattern, or combination thereof. Additionally, this coating material may either fully coat the surface layer and/or the coating may be applied to at least a portion of the surface layer such that they are not fully coated.
- a process for forming a fiber-cement composite sheet having smooth-surface comprising the steps of a) providing at least two slurry compositions separately in at least two mixing tanks for forming the fiber-cement composite sheet comprising at least two composite layers, where
- the first slurry composition is used for forming a base layer of the fibercement composite sheet
- the first slurry composition in step a) comprises: a cement material in an amount from 1 to 10 % w/v; a siliceous material in an amount from 1 to 10 % w/v; a filler in an amount from 0.1 to 10 % w/v; a long fiber in an amount from 0.1 to 2 % w/v; and a medium up to 100 % w/v; and wherein the second slurry composition
- the second slurry composition further comprises the long fiber in an amount from 0.005 to 1.5 % w/v.
- the first slurry composition comprises: the cement material in an amount from 1 to 8 % w/v; the siliceous material in an amount from 1 to 8 % w/v; the filler in an amount from 0.3 to 5 % w/v; the long fiber in an amount from 0.1 to 1.5 % w/v; and the medium up to 100 % w/v.
- the second slurry composition comprises: the cement material in an amount from 1.7 to 7 % w/v; the siliceous material in an amount from 1.7 to 7 % w/v; the filler in an amount from 0.3 to 2 % w/v; the long fiber in an amount from 0.15 to 1.1 % w/v; the short fiber in an amount from 0.01 to 0.2 % w/v; and the medium up to 100 % w/v.
- the thickness ratio of the base layer to the surface layer is from 1 :0.1 to 1 : 1.
- the thickness ratio of the base layer to the surface layer is from 1 :0.4 to 1 :0.6.
- the long fiber is a fiber having an average length from 1.5 to 4 mm.
- the long fiber is a fiber having an average diameter from 20 to 40 pm.
- the short fiber is a fiber having an average length from 0.5 to 1.5 mm.
- the short fiber is a fiber having an average diameter from 5 to 15 pm.
- the first slurry composition further comprises an additive in an amount from 0.1 to 30 % wt of the cement material, where the additive is selected from pigment, preservative, luminescence, bulking agent, defoaming agent, dispersing agent, reinforcing agent, flow rate adjusting agent, flame resisting agent, adhesive, anti-slip agent, and catalyst or inhibitor, or mixture thereof.
- the additive is selected from pigment, preservative, luminescence, bulking agent, defoaming agent, dispersing agent, reinforcing agent, flow rate adjusting agent, flame resisting agent, adhesive, anti-slip agent, and catalyst or inhibitor, or mixture thereof.
- the second slurry composition further comprises the additive in an amount from 0.1 to 30 % wt of the cement material, where the additive is selected from pigment, preservative, luminescence, bulking agent, defoaming agent, dispersing agent, reinforcing agent, flow rate adjusting agent, flame resisting agent, adhesive, anti-slip agent, and catalyst or inhibitor.
- the step c) can be repeated to increase the thickness of the base layer and the surface layer.
- said process further comprises the step of forming a coating material on the surface layer, where the amount of the coating material is 1.8 to 2.5 g/cm 2 .
- step a) further comprises a step of providing a third slurry composition for forming at least one intermediate layer, where the slurry composition comprising: the cement material in an amount from 1 to 10 % w/v; the siliceous material in an amount from 1 to 10 % w/v; the filler in an amount from 0.5 to 10 % w/v; and the medium up to 100 % w/v.
- the slurry composition for forming the intermediate layer further comprises a fiber in an amount from 0.005 to 1.2% w/v, where the fiber is selected from long fiber, short fiber, recycled fiber, or combination thereof.
- a smooth-surface fiber-cement composite sheet formed by a process comprising the steps of: a) providing at least two slurry compositions separately in at least two mixing tanks for forming the fiber-cement composite sheet comprising at least two composite layers, where
- the first slurry composition is used for forming a base layer of the fibercement composite sheet
- the first slurry composition in step a) comprises: a cement material in an amount from 1 to 10 % w/v; a siliceous material in an amount from 1 to 10 % w/v; a filler in an amount from 0.1 to 10 % w/v; a long fiber in an amount from 0.1 to 2 % w/v; and a medium up to 100 % w/v; and wherein the second slurry composition
- the first slurry composition comprises: the cement material in an amount from 1 to 8 % w/v; the siliceous material in an amount from 1 to 8 % w/v; the filler in an amount from 0.3 to 5 % w/v; the long fiber in an amount from 0.1 to 1.5 % w/v; and the medium up to 100 % w/v.
- the second slurry composition comprises: the cement material in an amount from 1.7 to 7 % w/v; the siliceous material in an amount from 1.7 to 7 % w/v; the filler in an amount from 0.3 to 2 % w/v; the long fiber in an amount from 0.15 to 1.1 % w/v; the short fiber in an amount from 0.01 to 0.2 % w/v; and the medium up to 100 % w/v.
- the step c) has a thickness ratio of the base layer to the surface layer from 1 :0.1 to 1 : 1.
- the step c) has a thickness ratio of the base layer to the surface layer from 1 :0.4 to 1 :0.6.
- the long fiber is a fiber having an average length from 1.5 to 4 mm.
- the long fiber is a fiber having an average diameter from 20 to 40 pm.
- the short fiber is a fiber having an average length from 0.5 to 1.5 mm.
- the short fiber is a fiber having an average diameter from 5 to 15 pm.
- the first slurry composition comprises an additive from 0.1 to 30 % wt of the cement material, where the additive is selected from pigment, preservative, luminescence, bulking agent, defoaming agent, dispersing agent, reinforcing agent, flow rate adjusting agent, flame resisting agent, adhesive, anti-slip agent, and catalyst or inhibitor, or mixture thereof.
- the second slurry composition comprises the additive from 0.1 to 30 % wt of the cement material, where the additive is selected from pigment, preservative, luminescence, bulking agent, defoaming agent, dispersing agent, reinforcing agent, flow rate adjusting agent, flame resisting agent, adhesive, anti-slip agent, and catalyst or inhibitor.
- the step c) can be repeated to increase the thickness of the base layer and the surface layer on the roller.
- said fiber-cement composite sheet has a roughness from 7 to 13 pm.
- the fiber-cement composite sheet further comprises a coating material, where the amount of the coating material is 1.8 to 2.5 g/cm 2 .
- the forming in step a) further comprises a step of providing a third slurry composition for forming at least one intermediate layer, where the slurry composition comprisesing: the cement material in an amount from 1 to 10 % w/v; the siliceous material in an amount from 1 to 10 % w/v; the filler in an amount from 0.5 to 10 % w/v; and the medium up to 100 % w/v.
- the slurry composition for forming the intermediate layer further comprises fiber in an amount from 0.005 to 1.2% w/v, where the fiber is selected from long fiber, short fiber, recycled fiber, or combination thereof.
- a process for forming a fiber-cement composite sheet according to an exemplary embodiment of the invention uses a Hatschek process to produce the fiber-cement composite sheet with smooth-surface while still having high strength. Therefore, it requires development of a process including a slurry composition used for forming each layer of the fiber-cement composite sheet including a base layer and a surface layer as shown in Figure 1.
- the process according to the present invention can produce a fiber-cement composite sheet having the base layer for providing high strength comparable to conventional fiber-cement composite sheet, while the upper surface layer has a smooth surface without requirement of additional post-process and/or post-treatment.
- slurry compositions for surface layer and/or base layer needs to consider mechanical properties of such layers. This is because fatigue failure of layer can happen from impact force according to fatigue load from external force such as the weight of construction structure. This affects the fatigue of a material which causes breaking. Therefore, in the production of fiber-cement composite sheet to have smooth surface and be capable of tolerating an impact damage, there are several factors to be considered; for example, slurry composition and a thickness ratio of base layer to surface layer, which will be described as follows.
- the material of the base layer should have flexible property in order to reduce a stiffness and brittleness of the base layer.
- Long and/or large fibers are used for providing strength and flexibility of the fiber-cement composite sheet in order to withstand impact force, therefore the base layer of this invention is designed to have the thickness more than 50% of total thickness in order to give ample strength for the fiber-cement composite sheet.
- the surface layer of the fiber-cement composite sheet is provided on the base layer.
- the smoothness of the surface layer according to the exemplary embodiment of the invention can be modified by changing types or adjusting amounts of compositions.
- the compositions include cement material (selected from, but not limited to, portland cement, hydraulic cement, white portland cement, and black portland cement), siliceous materials (selected from, but not limited to, glass sand, ground sand, river sand, ash, pozzolan, and shale), additives (selected from, but not limited to, calcium carbonate, flying ash, clay, calcium sulfate, and waste obtained from the production of reinforcing material), and fiber (selected from, but not limited to, natural fiber, carbon fiber, fiberglass, and glass fiber).
- cement material selected from, but not limited to, portland cement, hydraulic cement, white portland cement, and black portland cement
- siliceous materials selected from, but not limited to, glass sand, ground sand
- the fiber used for the surface layer is short fiber since the short fiber can improve smoothness of the surface layer and reduce the porousness of the surface when coated with coating material (e.g. color). More smoothness of the surface layer would help reduce the adsorption of the coating material thereon and able to save the amount of coating material used.
- coating material e.g. color
- Figure 2 shows characteristic of a long fiber and short fiber used in the base layer or the surface layer according to the exemplary embodiment of the invention.
- the fiber is characterized using a fiber analyzer (Valmet FS5).
- the long fiber has average length from 1.5 to 4 mm, and diameter from 20 to 40 pm.
- the long fiber can be obtained from, for example, unbleached crafted paper or sulfite membrane.
- the short fiber has average length from 0.5 to 1.5 mm, and diameter from 5 to 15 pm.
- the short fiber can be obtained from, for example, hard wood pulp, and/or broad leaf fiber (e.g. Eucalyptus, Racosperma mangium , Acacia mangium, and Earleaf acacia), and/or recycled fiber (for example waste wood, waste paper pulp, recycled paper pulp, or recycled paper).
- average length of the fiber means to include the mean, median, or mode of the total length of the fiber used in the preparation of the slurry composition for forming the fiber-cement composite sheet.
- average diameter means the mean, median, or mode of the total diameter of the fiber used in the preparation of the slurry composition for forming the fiber-cement composite sheet.
- the Hatschek process used for forming the fiber-cement composite sheet is shown in Figure 3.
- Two slurry compositions are used in this process, where a first slurry composition is used for forming the base layer composite material and a second slurry composition is used for forming the surface layer composite material of the fiber-cement composite sheet.
- the obtained fiber-cement composite sheet has smooth-surface layer that can save the amount of coating material used and has the base layer for strength.
- the scope of the present invention is not intended to limit to use only two types of slurry compositions for forming the base layer and the surface layer, as shown in the example according to the invention.
- a person skilled in the art or related fields can use a slurry composition different from the first and second slurry compositions without being construed as significantly different from the detailed description of the present invention.
- the modification or addition of the number or type of said slurry composition includes but is not limited to the adjustment of the composition ratio of the short fiber to long fiber in base layer, surface layer, and the adjustment of the thickness of each layer.
- the process according to the present invention comprises the following steps.
- Step A two slurry compositions are separately prepared in the mixing tanks.
- the slurry compositions is used for forming the base layer and the surface layer of the fibercement composite sheet. This step can be divided into 3 following sub-steps.
- the cement material, siliceous material, and additive are filled in the storage tanks (such as silos) separately.
- the long fiber is dispersed in water before being stored in the storage tank for further use as the composition for the base layer and/or surface layer.
- the short fiber is dispersed in water before being stored in the storage tank for further use as the composition for the base layer and/or surface layer.
- the first slurry composition is prepared by feeding the long fiber (which is dispersed in water obtained from the previous step), the cement material, siliceous material, and additive into the first mixing tank.
- the obtained slurry composition has the solid content from 5 to 20% w/v.
- the first slurry composition comprises: the cement material in an amount from 1 to 10 % w/v; the siliceous material in an amount from 1 to 10 % w/v; the filler in an amount from 0.1 to 10 % w/v; the long fiber in an amount from 0.1 to 2 % w/v; and the medium up to 100 % w/v.
- the second slurry composition is prepared by feeding the short fiber and long fiber, which is dispersed in water obtained from the previous step, with the cement material, siliceous material, and additive in the second mixing tank.
- the second slurry composition comprises: the cement material in an amount from 1 to 10 % w/v; the siliceous material in an amount from 1 to 10 % w/v; the filler in an amount from 0.1 to 10 % w/v; the short fiber in an amount from 0.005 to 1.5 % w/v; and the medium up to 100 % w/v.
- the second slurry composition may further comprise long fiber in an amount from 0.005 to 1.5 % w/v.
- Step B Each slurry composition obtained from step a) is separately fed from each mixing tank into at least two sieves, wherein each sieve contains one slurry composition.
- the first control unit (not shown in the Figure 3) controls feed of the first slurry composition in the first mixing tank to 1 to 7 sieves for forming into the base layer of the fiber-cement composite sheet. For example, as shown in Figure 3, the first slurry composition is fed into 4 sieves.
- the second control unit (not shown in the Figure 3) controls feed of the second slurry composition in the second mixing tank to 1 to 4 sieves for forming into the surface layer of the fiber-cement composite sheet.
- the second slurry composition is fed into 2 sieves.
- the number of sieves used in the process can be adjusted such that the fiber-cement composite sheet with suitable strength surface and smooth-surface is obtained.
- the number of sieves can be from, but not limited to 2, 4, 6, or 8 sieves, preferably 6 to 8 sieves.
- the example of the fiber-cement composite sheet obtained from the process according to the exemplary embodiment of the invention is shown in Figure 4.
- the process uses the 6-sieves Hatschek process in which 4 sieves are for the first slurry composition and 2 sieves are for the second slurry composition.
- Step C Each composite layer of the fiber-cement composite sheet is formed using Hatschek process.
- This process uses the conveyor belt to roll through the sieves and forms each layer from the slurry composition in each sieve, where water of the layers is reduced by pressure to form the fiber-cement composite sheet on the surface of the conveyor belt. Then the conveyor belt further transports the fiber-cement composite sheet to the roller.
- the conveyor belt rolls through to 4 sieves of the first slurry composition to form the base layer composite material from the first slurry composition. Then, the conveyor belt further rolls through 2 sieves of the second slurry composition to form the surface layer of the composite material from the second slurry composition. Then, the moisture is removed before being conveyed to the roller.
- Step C can be repeated, for example, from 1 to 14 cycles in order to increase the thickness of the fiber-cement composite sheet on the roller.
- Each cycle would increase the thickness (e.g. from 1 to 5 mm) of base layer and surface layer of the fibercement composite sheet on the roller so that the thickness of the fiber-cement composite sheet meets the requirements.
- the thickness ratio of base layer to surface layer may be controlled to be 1 :0.1 to 1 : 1.
- an intermediate layer may be added using a third slurry composition different from the first and second slurry compositions (as shown in Figure 1C) in order to obtain the fiber-cement composite sheet.
- the slurry composition for forming into the intermediate layer may comprise the following: the cement material in an amount from 1 to 10 % w/v; the siliceous material in an amount from 1 to 10 % w/v; the filler in an amount from 0.5 to 10 % w/v; and the medium up to 100 % w/v.
- the slurry composition for forming the intermediate layer may further comprise the long fiber in an amount from 0.005 to 1.2 % w/v, short fiber in an amount from 0.005 to 1.2 % w/v, and the recycled fiber from 0.005 to 1.2 % w/v.
- the example of the recycled fiber includes but is not limited to fiber obtained from cardboard box recycling or fiber obtained from newspaper recycling.
- Step D The fiber-cement composite sheet obtained from Step C is cured by air curing technique in a moisture control room at the temperature of 40 to 80 °C, relative moisture 50 to 100 % RH, for 8 to 24 hours.
- -the fiber-cement composite sheet may be cured by air curing followed by steam curing at the pressure of 5 to 15 bars for 8 to 20 hours may be used in order to cure the fiber-cement composite sheet.
- Figure 4 shows the fiber-cement composite sheet obtained from the process of the present invention. It can be seen that the obtained fiber-cement composite sheet (sample B-8, sample C-l) has different layers of base layer and surface layer, where the base layer provides mechanical strength of the fiber-cement composite sheet, while the surface layer provides smooth-surface.
- the surface layer as shown in sample B-8 and sample C-l may have roughness from 7 to 13 pm (analyzed by laser technique (Gapgun)).
- control sample 1 control sample 1
- SEM scanning electron microscope
- the obtained panel has a smooth-surface, which helps significantly reduce amounts of coating material to be used for coating the obtained panel.
- the amount of coating material to be used is reduced to only 1.8 to 2.5 g/cm 2 when compared to the fiber-cement composite sheet obtained from the conventional Hatschek process that requires amounts of coating material about 2.7 to 3 g/cm 2 . Accordingly, it is possible to reduce the use of coating material by more than 10 %, preferably by more than 20 %, and more preferably by more than 28 %.
- the first slurry composition or the second slurry composition may further comprise one or more additives in an amount from 0.1 to 30 % wt of the cement material in order to adjust and/or improve properties of the fiber-cement composite sheet.
- the additive can be selected from, but not limited to, pigment, preservative, luminescence, bulking agent, defoaming agent, dispersant, reinforcing agent, flow rate adjusting agent, flame retardant, adhesive, anti-slip agent, and catalyst or inhibitor, or combination thereof in order to increase the properties according to the purpose of use such as increasing the surface color of the product or increasing the adhesive property as shown in figure 7 without any intention to limit the scope of the invention.
- the additive does not include coating material.
- the properties of the fiber-cement composite sheet obtained from the process according to the exemplary embodiment of the invention would be compared to the fibercement composite sheet obtained from the conventional Hatschek process using only one slurry composition, where the testing details are as follows.
- Control sample 1 and control sample 2 were fiber-cement composite sheet formed by the conventional Hatschek process using one slurry composition.
- Sample A-l, sample B-l, sample C-l were fiber-cement composite sheet formed by the process of the exemplary embodiment of the invention using two slurry compositions, wherein:
- Control sample 1 was obtained from the conventional Hatschek process with one slurry composition having only long fiber.
- the amount of coating material on control sample 1 and mechanical properties were set as standard reference.
- Control sample 2 was obtained from the conventional Hatschek process with one slurry composition having both long fiber and short fiber.
- the obtained fiber cement composite sheet of control sample 2 could reduce coating material usage by about 23%.
- its mechanical property was brittle because the toughness of the control sample 2 was reduced by 48 %.
- Sample A-l, Sample B-l, Sample C-l were obtained from the process of the exemplary embodiment of the invention using two slurry compositions, having only long fiber for the base layer and only short fiber for the surface layer.
- sample A-l thickness ratio of about 1 :0.25
- Sample B-l which has the thickness ratio of base layer to surface layer of about 1 :0.49 could reduce the coating material usage by about 21 % and increase the toughness property by 51 % when compared to control sample 1.
- sample C-l which has the thickness ratio of base layer to surface layer of about 1 : 1 could reduce the coating material usage by about 22 % and increase the toughness property by 18 %.
- sample B-l which has the thickness ratio of base layer to surface layer of about 1 :0.49 provided the highest toughness and reduced the coating material usage by 21 %.
- Table 1 Compositions of samples of the fiber-cement composite sheet
- Table 2 Mechanical properties of the fiber-cement composite sheet obtained from samples having different thickness ratio of base layer to surface layer
- Sample B-2, B-3, and B-4 were formed from two slurry compositions according to the process in the exemplary embodiment of the invention.
- the compositions of cement material, siliceous material, and additive were adjusted for the surface layer.
- the results show that sample B-2 could reduce the coating material usage by about 11 % when compared with the control sample 1, but the sample B-2 was quite tough and had low stability, which was not suitable for the product that needs high strength such as ceilings and floors.
- Sample B-3 could reduce the coating material usage by about 16 % and gave the strength similar to control sample 1. Moreover, sample B-4 could reduce the coating material usage by about 23 % and gave the strength similar to the control sample 1 as well. Therefore, the study found that composition used for sample B-4 can reduce the amount of coating material and also maintain the strength property.
- Table 3 Samples having thickness ratio of base layer to surface layer of 1 :0.49, where each sample has different composition of cement material, siliceous material, and additive of the surface layer
- Table 4 Testing of fiber-cement from samples having thickness ratio of base layer to surface layer of 1 :0.49, where each sample has different composition of cement material, siliceous material, and additive of the surface layer
- the thickness ratio of base layer to surface layer was about 1 :0.49.
- the surface layer was determined to have cement material of 4.2 % w/v, siliceous material of 4.2 % w/v, and additive of 1 % w/v.
- the composition between long fiber and short fiber was adjusted in order to evaluate the mechanical properties and coating material usage.
- Table 5 and Table 6 shows the slurry compositions and the test results respectively.
- Sample B-5, B-6, B-7, B-8, and comparative sample B-9 were formed from the two slurry compositions according to the process in the exemplary embodiment of the invention.
- the composition of long fiber and short fiber was adjusted for different smoothness of surface layers. From the results, it was found that sample B-5 could reduce the coating material usage by about 25 % and gave the strength similar to the control sample 1.
- Sample B-6 could reduce the coating material usage by about 26 % and gave the strength similar to the control sample 1.
- Sample B-7 could reduce the coating material usage by about 26 % and gave the strength higher than the control sample 1.
- Sample B-8 could reduce the coating material usage by about 28 % and gave the strength higher than the control sample 1.
- comparative sample B-9 could not reduce the coating material usage when compared with control sample 1.
- Table 5 Samples having thickness ratio of base layer to surface layer of 1 :0.49, where each sample has different compositions of long fiber and short fiber of the surface layer
- Table 6 Testing results of fiber-cement composite sheet from samples having thickness ratio of base layer to surface layer of 1 :0.49 having different compositions of long fiber and short fiber of the surface layer
- fiber-cement composite sheet samples formed by the process according to the exemplary embodiment of the invention could be used in work that needs smooth-surface which also gave same strength compared to the cement sheet according to the control sample, but the fiber-cement composite sheet according to the exemplary embodiment of the invention provided the smoothness of the surface layer and could save coating material usage up to about 28 %.
Abstract
La présente invention concerne un procédé de formation d'une feuille composite de fibrociment à l'aide de deux compositions de boue. La première composition de boue est destinée à former une couche de base et une seconde composition de boue est destinée à former une couche de surface afin d'obtenir une feuille composite de fibrociment présentant une surface lisse. Il en résulte une réduction significative de l'utilisation d'un matériau de revêtement, mais présente toujours la couche de base pour la résistance sans nécessiter d'autres étapes de production.
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GB2161415A (en) * | 1984-07-06 | 1986-01-15 | Pilkington Brothers Plc | Process for making cement composite materials |
WO2002070218A1 (fr) * | 2001-03-02 | 2002-09-12 | James Hardie Research Pty Limited | Procede et appareil pour produire un materiau sous forme de feuille laminee par projection |
WO2016102116A1 (fr) * | 2014-12-22 | 2016-06-30 | Fermacell Gmbh | Plaque coupe-feu et procédé de fabrication de ladite plaque coupe-feu |
WO2017001230A2 (fr) * | 2015-06-29 | 2017-01-05 | Eternit Nv | Procédé de hatschek |
WO2019068829A1 (fr) * | 2017-10-06 | 2019-04-11 | Etex Services Nv | Produits de fibrociment améliorés et procédés de production associés |
WO2021048020A1 (fr) * | 2019-09-09 | 2021-03-18 | Etex Services Nv | Produits de fibrociment améliorés et procédés de production associés |
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