# US 9,435,124 B2 · Cementitious exterior sheathing product having improved interlaminar bond strength

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- Number: US 9,435,124 B2
- Document ID: US9435124B2
- Status: Granted
- Kind: B2
- Application number: 13/439,542
- Filed: 2012-04-04
- Published: 2012-08-02
- Granted: 2016-09-06
- Earliest claimed: 2002-11-05
- Assignees: Plycem USA, Inc.
- Applicants: William Paul Bezubic, Jr.
- Inventors: William Paul Bezubic, Jr.
- Web page: https://patentgrep.com/patent/US9435124B2

## CPC

- B32B 13/02: with fibres or particles {being present as additives in the layer}
- B28B 1/526: {by delivering the materials on a conveyor of the endless-belt type}
- B28B 1/527: {by delivering the materials on a rotating drum, e.g. a sieve drum, from which the materials are picked up by a felt}
- B28B 7/46: for humidifying or dehumidifying
- C04B 28/04: Portland cements
- C04B 41/009: {characterised by the material treated}
- C04B 41/483: {Polyacrylates}
- C04B 41/63: Macromolecular compounds
- E04C 2/04: of concrete or other stone-like material; of asbestos cement; {of cement and other mineral fibres}(E04C2/26 takes precedence; material or manufacture B28, C04)
- E04D 1/16: of ceramics, glass or concrete, with or without reinforcement
- E04F 13/0733: {for corners}
- E04F 13/141: {with an outer layer of concrete (E04F13/147 takes precedence)}
- E04F 13/16: of fibres or chips, e.g. bonded with synthetic resins {, or with an outer layer of fibres or chips (E04F13/0864 takes precedence)}
- E04F 15/10: of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite {tiles}, hardboard {, or with a top layer of other materials}
- B32B 2038/0076: {Curing, vulcanising, cross-linking}
- B32B 2250/05: 5 or more layers
- B32B 2307/7265: Non-permeable
- B32B 2419/00: Buildings or parts thereof
- C04B 2111/00612: {as one or more layers of a layered structure}
- C04B 2111/00637: {as glue or binder for uniting building or structural materials}
- C04B 2111/1018: {Gypsum free or very low gypsum content cement compositions}
- Y02W 30/91: Use of waste materials as fillers for mortars or concrete
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S)
- E04D: ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS (coverings of outer walls by plaster or other porous material E04F13/00)
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT

## Abstract

The present invention provides exterior building products, such as roofing and siding, shake, shingles, siding, sheathing, panels, planks, vertical siding, soffit panels, fencing, decking, fascia, corner posts, column corners and trim boards in which a plurality of cementitious layers are provided with an improved interlaminar bond by employing a resinous bond promoter, a rheological agent, mechanical means to distribute fibers in a direction which is perpendicular to the machine direction so as to bridge between layers in the product, or a combination thereof. These techniques help to increase interlaminar bond strength to improve the mechanical properties of the product. When certain resinous bond promoters are used, the additional benefits of water absorption resistance and pigmentation throughout the product can be provided with minimal expense. Improvements in interlaminar bond strength of about 10 46% were observed with a percent elongation improvement of about 7%.

## Claims

### Claim 1

An exterior siding member comprising a plurality of individual fibercement layers affixed to a rigid support member, wherein the individual fibercement layers comprise a curable non-gypsum cementitious material having fibers therein, and the layers are adhered to one another by one or more of interlaminar bond strength promoters, wherein one of the one or more interlaminar bond strength promoters comprises nano-sized magnesium alumino silicate and an acrylic based resin and water, wherein a ratio of the acrylic based resin to water is 5% to 50%.

### Claim 2

A cement-containing exterior siding member comprising:
(a) an elongated rigid support member comprising steel, said rigid support member having a wall-facing side and an exterior-facing side and a plurality of fastener receiving holes disposed therethrough; and
(b) a cement-containing layer bonded to said rigid support member, said cement-containing layer comprising a plurality of individual fibercement layers wherein the individual fibercement layers comprise a curable non-gypsum cementitious material having fibers therein, and the fibercement layers are adhered to one another by one or more of interlaminar bond strength promoters, wherein one of the one or more interlaminar bond strength promoters comprises nano-sized magnesium alumino silicate and an acrylic based resin and water, and wherein the cement-containing layer comprises an outwardly facing exterior-facing side.

### Claim 3 (depends on 2)

The cement-containing exterior siding member of claim 2, wherein said rigid support member comprises galvanized steel lath or galvanized and perforated steel sheet or plate.

### Claim 4 (depends on 2)

The cement-containing exterior siding member of claim 2, further comprising a resinous cement bond promoter to assist in bonding said cement-containing layer to said rigid support member.

### Claim 5 (depends on 2)

The cement-containing exterior siding member of claim 2, wherein said cement-containing layer comprises cellulosic fiber, silica sand, portland cement or a combination thereof.

### Claim 6

A cementitious exterior sheathing product comprising:
(a) a rigid metal support member having a wall-facing side and an exterior-facing side, a nail flange disposed along at least one of its outer edges, and a plurality of perforations defined through the rigid metal support member; and
(b) a cementitious layer bonded to said rigid support member, the cementitious layer extending through the plurality of perforations to lock said cementitious layer to said rigid support member, said cementitious layer comprising a plurality of individual fibercement layers wherein the individual fibercement layers comprise a curable non-gypsum cementitious material having fibers therein, and the fibercement layers are adhered to one another by one or more of interlaminar bond strength promoters, wherein one of the one or more interlaminar bond strength promoters comprises nano-sized magnesium alumino silicate and an acrylic based resin and water, wherein the cementitious layer exhibits a wood grain appearance.

### Claim 7

A cementitious exterior sheathing product comprising:
(a) a rigid metal support member having a wall-facing side and an exterior-facing side, a nail flange disposed along at least one of its edges, and a plurality of perforations defined through the rigid metal support member; and
(b) a cementitious layer disposed at least on a portion of said rigid support member and being laterally spaced apart from said nailing flange, the cementitious layer extending through the plurality of perforations to lock said cementitious layer to said rigid support member, said cementitious layer comprising a plurality of individual fibercement layers, wherein the individual fibercement layers comprise a curable non-gypsum cementitious material having fibers therein, and the fibercement layers are adhered to one another by one or more of interlaminar bond strength promoters, wherein one of the one or more interlaminar bond strength promoters comprises nano-sized magnesium alumino silicate and an acrylic based resin and water, wherein the cementitious layer exhibits a wood grain appearance, and said metal support member is at least partially embedded within said cementitious layer.

### Claim 8

An exterior siding member comprising:
(a) a plurality of individual fibercement layers, wherein the individual fibercement layers comprise a curable non-gypsum cementitious material having fibers therein, and the fibercement layers are adhered to one another by one or more of interlaminar bond strength promoters, wherein one of the one or more interlaminar bond strength promoters comprises nano-sized magnesium alumino silicate and an acrylic based resin and water;
(b) a rigid support member having a plurality of perforations defined therethrough, the cementitious material extending through the plurality of perforations to lock said fibercement layers to said rigid support member, the rigid support member also being bonded to one or more of the individual layers of the plurality of fibercement layers, the rigid support member having a wall-facing side and a nailing flange, wherein the nailing flange comprises a fastener receiving portion to receive fasteners for attaching the wall-facing side to a building;
wherein an exterior face of the siding member comprises a press imprinted wood grain texture.