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US 10,590,657 B2Granted
Fiber cement articles with ultra-smooth exterior surface and methods for manufacturing same
AssigneeJames Hardie Technology Limited
InventorsMarko Suput, William Munch
Life of this patent
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Abstract
Described herein are cementitious articles having an integrally formed exterior surface with ultra-smooth finish and reduced porosity and/or thickness relative to the core of the cementitious article. Described herein are also techniques and methods for producing fiber cement articles having a thin exterior shell characterized by improved smoothness and reduced porosity.
Claims19
A variable porosity fiber cement article comprising:
- a high porosity fiber cement core having a porosity between about 9% and 15%;
- and
- an integrally formed low porosity exterior shell having a porosity between about 8% and 14%, wherein the integrally formed low porosity exterior shell has a thickness of 0.02 to 3% of a thickness of the high porosity fiber cement core.
A fiber cement article comprising:
- a fiber cement substrate comprising two opposing lateral faces and at least one side surface extending therebetween;
- an integrally formed fiber cement shell disposed on at least one of the lateral faces of the fiber cement substrate, said integrally formed fiber cement shell covering a substantial portion of the at least one lateral face, said integrally formed fiber cement shell having a thickness between about 50 and 150 μm;
- and
- wherein the integrally formed fiber cement shell has a lower porosity value than that of the fiber cement substrate and a lower surface roughness value than that of the at least one side surface of the fiber cement substrate, thereby providing a protective and smooth integrally formed exterior surface for the fiber cement article.
1 more element
A fiber cement article comprising:
- a substrate comprising a fiber cement composition including cellulose fibers, the substrate further comprising two opposing lateral faces and at least one side surface extending therebetween;
- an integrally formed shell comprising the fiber cement composition, the integrally formed shell disposed on at least one of the lateral faces of the substrate, said integrally formed shell covering a substantial portion of the at least one lateral face and having a thickness between about 50 and 150 μm;
- and
- wherein the integrally formed shell has a lower porosity value than that of the substrate and a lower surface roughness value than that of the at least one side surface of the substrate, thereby providing a protective and smooth integrally formed exterior surface for the fiber cement article.
1 more element
A fiber cement article comprising:
- a substrate comprising a fiber cement composition including cellulose fibers, the substrate further comprising two opposing lateral faces and at least one side surface extending therebetween;
- an integrally formed shell comprising the fiber cement composition, the integrally formed shell disposed on at least one of the lateral faces of the substrate, said integrally formed shell covering a substantial portion of the at least one lateral face and having a thickness that is 0.02 to 3% of a thickness of the substrate;
- and
- wherein the integrally formed shell has a lower porosity value than that of the substrate and a lower surface roughness value than that of the at least one side surface of the substrate, thereby providing a protective and smooth integrally formed exterior surface for the fiber cement article.
1 more element
Dependencies are inferred from the claim text.