Source: http://www.google.com/patents/US7815841?dq=7565338
Timestamp: 2015-07-04 02:28:18
Document Index: 277866918

Matched Legal Cases: ['Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 05075809', 'Application No. 01973377', 'Application No. 01975765']

Patent US7815841 - Fiber cement composite materials using sized cellulose fibers - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsThis invention discloses a new technology related to cellulose fiber reinforced cement composite materials using cellulose fibers that are treated with inorganic and/or organic resins to make the fibers more hydrophobic, as well as other chemical treatments. This invention discloses four aspects of the...http://www.google.com/patents/US7815841?utm_source=gb-gplus-sharePatent US7815841 - Fiber cement composite materials using sized cellulose fibersAdvanced Patent SearchPublication numberUS7815841 B2Publication typeGrantApplication numberUS 10/757,330Publication dateOct 19, 2010Filing dateJan 13, 2004Priority dateOct 4, 2000Fee statusPaidAlso published asCA2424377A1, CA2424377C, CN1246246C, CN1473138A, EP1330420A2, US6676745, US20020059886, US20040145078, WO2002028795A2, WO2002028795A3Publication number10757330, 757330, US 7815841 B2, US 7815841B2, US-B2-7815841, US7815841 B2, US7815841B2InventorsDonald J. Merkley, Caidian LuoOriginal AssigneeJames Hardie Technology LimitedExport CitationBiBTeX, EndNote, RefManPatent Citations (107), Non-Patent Citations (58), Referenced by (3), Classifications (50), Legal Events (5) External Links: USPTO, USPTO Assignment, EspacenetFiber cement composite materials using sized cellulose fibers
US 7815841 B2Abstract
1. A method of manufacturing a fiber reinforced cement composite material, consisting of:
providing unbleached cellulose fibers individualized to about 500 CSF;
treating at least a portion of the cellulose fibers in solution with about 10% by fiber mass with one or more sizing agents in the presence of water or an organic solvent for about 1 hour at ambient temperature at 1 atm and 4% pulp consistency, wherein the sizing agent comprises a hydrophilic functional group and a hydrophobic functional group, wherein the hydrophilic group chemically bonds to at least some of the hydrophilic sites on inner and outer surfaces of the fibers to form sized fibers, wherein the sizing agent substantially blocks the hydrophilic sites, thereby reducing the fibers' affinity toward water;
mixing about 8% by weight sized fibers with about 35% cementitious binder and about 57% ground silica to form a fiber cement mixture;
forming the fiber cement mixture into a fiber cement article of a pre-selected shape and size;
precuring the fiber cement article for about 8 hours at ambient temperature so as to form the fiber reinforced composite building material; and
autoclaving the fiber cement article for about 12 hours at about 180� C.
2. A method of manufacturing a fiber reinforced cement composite material, consisting of:
treating at least a portion of the cellulose fibers in solution with about 5% by fiber mass with one or more sizing agents in the presence of water or an organic solvent for about 30minutes at ambient temperature at 1 atm and at 4% pulp consistency, wherein the sizing agent comprises a hydrophilic functional group and a hydrophobic functional group, wherein the hydrophilic group chemically bonds to at least some of the hydrophilic sites on inner and outer surfaces of the fibers to form sized fibers, wherein the sizing agent substantially blocks the hydrophilic sites, thereby reducing the fibers' affinity toward water;
drying said article to a density of 1.3 g/cm3.
3. A method of manufacturing a fiber reinforced cement composite material, consisting of:
providing unbleached cellulose fibers individualized to about 450 CSF;
treating at least a portion of the cellulose fibers in solution with about 10% by fiber mass with one or more sizing agents in the presence of water or an organic solvent for about 1 hour at ambient temperature at 1 atm and at 30% pulp consistency, wherein the sizing agent comprises a hydrophilic functional group and a hydrophobic functional group, wherein the hydrophilic group chemically bonds to at least some of the hydrophilic sites on inner and outer surfaces of the fibers to form sized fibers, wherein the sizing agent substantially blocks the hydrophilic sites, thereby reducing the fibers' affinity toward water;
4. A method of manufacturing a fiber reinforced cement composite material, consisting of:
providing bleached cellulose fibers individualized to about 500 CSF;
treating at least a portion of the cellulose fibers with about 5% by fiber mass with a sizing agent consisting essentially of n-octyltriethoxysilane by spraying said bleached cellulose fibers at ambient temperature with said sizing agent,
mixing about 10% by weight sized fibers with about 39% cementitious binder and about 39% ground silica, about 10% of at least one density modifier, and about 1.5% additives, to form a fiber cement mixture;
extruding the fiber cement mixture to a fiber cement article of a pre-selected shape and size;
curing the fiber cement article for about 24 hours at about 180� C., the article having a density of about 0.9 g/cm3.
5. A method of manufacturing a fiber reinforced cement composite material, consisting of:
providing bleached cellulose fibers individualized to about 400 CSF and a 4% consistency;
treating at least a portion of the cellulose fibers with about 10% by fiber mass with a sizing agent consisting essentially of n-octyltriethoxysilane at about 30 C under 1 atm with said sizing agent, mixing about 7% by weight sized fibers with about 30% cementitious binder and about 63% ground silica to form a fiber cement mixture;
precuring the fiber cement article for about 8 hours at ambient temperature; and curing the fiber cement article for about 12 hours at about 180� C., the article having a density of about of 1.3 g/cm3. Description
This application is a divisional application of U.S. application Ser. No. 09/969,742 filed Oct. 2, 2001, now U.S. Pat. No. 6,676,745, entitled “Fiber Cement Composite Materials Using Sized Cellulose Fibers.” This application also claims benefit of U.S. Provisional Application No. 60/237,850, filed on Oct. 4, 2000, U.S. Provisional Application No. 60/237,783, filed on Oct. 4, 2000, and U.S. Provisional Application No. 60/241,212, filed on Oct. 17, 2000, the entirety of each of which is hereby incorporated by reference.
The preferred embodiments of the present invention relates generally to the chemical treatment of cellulose fibers in order to improve their resistance to water and/or environmental degradation for use in a composite building material. These embodiments include not only the use of sized cellulose fibers, as described in further detail below, but also other chemical treatments, such as the loading of fibers with insoluble substances to fill the void spaces of the fibers, and biocide treatment of fibers. Other chemical treatments to improve a building material's final properties are also contemplated as being within the scope of this invention. For example, chemical treatments to lower COD content in a fiber are described in Applicant's co-pending application entitled METHOD AND APPARATUS FOR REDUCING IMPURITIES IN CELLULOSE FIBERS FOR MANUFACTURE OF FIBER REINFORCED CEMENT COMPOSITE MATERIALS, Ser. No. 09/970,389 filed, Oct. 2, 2001, the entirety of which is hereby incorporated by reference. It will be appreciated that the aspects of the present invention are not applicable solely to cellulose fiber reinforced cementitious products, and accordingly, the chemical treatments may be applied to building materials reinforced with other fibers in non-cement products as well. The main treatments, in addition to the later described sized fiber treatment, fall into two additional groups, which will now be described in more detail. These are loaded fibers and biocide treated fibers:
In one preferred embodiment, this invention relates to the application of loaded, individualized cellulose fibers into cementitious cellulose fiber reinforced building materials. The loaded cellulose fibers generally comprise individualized cellulose fibers filled with one or more insoluble chemical compounds. Organic and/or inorganic compounds are preferably incorporated in the water conducting channels and voids present in the cellulose fiber lumens and cell walls. The loading methods may include chemical treatments such as chemical reactions, physical deposition or a combination of both. Advantageously, the substances that are deposited inside the fibers inhibit the transfer of water along the water conducting channels and voids, which in turn inhibits water migration in the fiber cement composite material. The loaded fibers preferably have non-cellulose contents from about 0.5%-200% based on the oven dry weight of cellulose fibers. More preferably, the loaded fibers contain up to about 80% by weight of non-cellulose substances. The lumens in the fibers can be loaded using methods described in U.S. Pat. Nos. 4,510,020 and 5,096,539, the entirety of both of which are hereby incorporated by reference. Other loading methods may be used.
It will be appreciated that the above list of chemical compounds is merely illustrative of examples of substances that can be used for fiber loading. The loading substance can also be other suitable inorganic or organic compounds, or combinations thereof, depending on the particular attributes needed for the specific application of the fiber cement material. In one embodiment, calcium carbonate is loaded into the cellulose fibers using known methods of fiber loading such as those described in U.S. Pat. Nos. 5,223,090 and RE35,460, the entirety of both of which are hereby incorporated by reference.
about 10%-80% cementitious binder; about 20%-80% silica (aggregates); about 0%-50% density modifiers; about 0%-10% additives; and about 0.5%-20% loaded cellulose fibers or a combination of loaded cellulose fibers, and/or regular unloaded fibers, and/or natural inorganic fibers, and/or synthetic fibers. It will be appreciated that for fiber cement articles that are to be air-cured, higher amounts of cement may be used, for example 60%-90%, without incorporating any silica or aggregate. In autoclaved embodiments, a lower amount of cement can be used incorporating individualized, loaded cellulose fibers. In one embodiment, this autoclaved formulation comprises:
about 20%-50% cement, more preferably about 25%-45%, even more preferably about 35%; about 30%-70% fine ground silica, more preferably about 60%; about 0-50% density modifiers; about 0-10% additives, more preferably about 5%; and about 2%-20% fibers, more preferably about 10% fibers, wherein some fraction of the fibers is cellulose fibers loaded with inorganic and/or organic materials that reduce water flow in the fiber pore space; Preferably, the loaded fibers have a freeness of 150 to 750 degrees of Canadian Standard Freeness (CSF) in accordance with TAPPI method T 227 om-99. The cementitious binder and aggregate have surface areas of about 250 to 400 m2/kg and about 300 to 450 m2/kg, respectively. The surface area for both the cement and silica is tested in accordance with ASTM C204-96a.
The water conducting channels and voids in the cellulose fibers lumens and cell walls are preferably filled with one or more chemical compounds using loading techniques such as chemical reactions and physical deposition or a combination of both, as described above. These loading techniques preferably occur in the presence of water or an organic solvent, with the loading of the fibers preferably occurring upon contact of the chemical compounds with the cellulose fibers. More preferably, the loading techniques occur at ambient temperatures, or less than about 100� C. In the chemical loading process, several soluble components will dissolve in the pulp slurry and penetrate into the fiber cell walls. Reactions are triggered by changing pH, temperature, reagent dosages, radiation, pressure, ionic strengths, or other conditions. As a result, insoluble reaction products are formed and deposited inside the fibers. Examples of chemical deposition are described in U.S. Pat. Nos. 5,223,090 and RE 35,460, where soluble Ca(OH)2 is first dissolved in a pulp slurry and then CO2 gas is bubbled through the slurry. Ca(OH)2 will react with CO2 to form insoluble CaCO3 inside the fibers. Fiber loading by physical deposition is usually accomplished without chemical reaction involvement. Often, the fiber loading is accomplished by a combination of both chemical and physical depositions.
Further details regarding the loading of fibers are described in Applicant's copending application entitled FIBER CEMENT COMPOSITE MATERIALS USING CELLULOSE FIBERS LOADED WITH INORGANIC AND/OR ORGANIC SUBSTANCES, Ser. No. 09/969,957, filed Oct. 2, 2001, the entirety of which is hereby incorporated by reference. Additional details regarding the fabrication of fiber cement articles using the formulations mentioned above are described below with respect to the sized fiber embodiments.
Further details regarding biocide treated fibers are described in Applicant's copending application entitled FIBER CEMENT COMPOSITE MATERIALS USING BIOCIDE TREATED DURABLE CELLULOSE FIBERS, Ser. No. 09/969,964, filed Oct. 2, 2001, the entirety of which is hereby incorporated by reference. The formulations of the biocide treated fibers are similar to that described above for the loaded fibers, with the loaded fibers being replaced with biocide treated fibers. Moreover, the methods of manufacturing building materials incorporating biocide treated fibers and other aspects are similar to that of the sized fibers, described below.
organic resins such as natural or petroleum waxes, polyolefins, acrylics, epoxies, silane derivatives of all kinds and in all formulations, alkoxylsilane of all kinds and in various formulations, silicone emulsions of all kinds and in various formulations, acrylic latexes of all kinds, styrene butadiene rubber emulsions of all kinds, and other polymer latex and resins commonly used to alter surface characteristics of cellulose fibers; water soluble sizing agents that are common to the paper industry such as rosin acids, alum, starches, gums, casein, soya protein, alkyl ketene dimers (AKD) of all kinds and in all formulations, alkenyl succinic anhydrides (ASA) of all kinds and in all formulations, stearic acids of all kinds and in all formulations. The fibers are preferably treated with one or more compounds listed above, depending on the particular attributes needed for a specific application of the fiber cement composite material. Examples of commercially available chemicals that can be used include, but are not limited to:
Dow Chemicals Latex RAP900NA, PP722HS, and PB6638 Valspar EPS2718, EPS2708 and EPS2102 ChemRex Enviroseal 100, Enviroseal 100 plus, Enviroseal 40, Enviroseal 7, Hydrozo 100 and Hydrozo 100 plus Dow Coming Emulsions 2-7195 and 2-8002; Dow Coming polymers 2-8040 and 2-8630 Euclid Chemical Euco-Guard VOX, Eucon 37 Cresset Chemical Co. C-378 Clariant Prosil 9202 Pro-Seal DP-36 The sizing agents can be in a dry form such as powders, or wet form such as emulsions, dispersions, latexes and solutions. When multiple sizing agents are applied, some can be in dry form and others in wet form. Moreover, the sizing agent of the preferred embodiments may also include other chemicals that are traditionally used to size paper fibers as disclosed in U.S. Pat. No. 5,096,539, which is hereby incorporated by reference in its entirety. Whether the sizing agents are in dry form or in wet form, when caused to react with the hydroxyl groups on the fibers, the reaction preferably occurs in the presence of water or an organic solvent to facilitate the reaction. It can be appreciated that the above lists of chemical compounds are merely illustrative examples of substances that can be used for sizing the fibers. The sizing agents can also be any other suitable inorganic or organic compounds, or combinations thereof, depending on the particular attributes needed for the specific application of the fiber cement material.
The cellulose fibers for sizing treatment can be unrefined/unfibrillated or refined/fibrillated cellulose pulps from sources, including but not limited to bleached, unbleached, semi-bleached cellulose pulp produced by various pulping techniques. The cellulose pulps can be made of softwood, hardwood, agricultural raw materials, recycled waste paper or any other forms of lignocellulosic materials.
fiber dispersion/fiberization (individualizing fibers); fibrillation (mechanical means to increase fiber surface area); fiber conditioning (dewatering, drying or dilution); treatment/sizing reactions with one or more sizing agents; removal of residual/excessive sizing agents; and conditioning of the sized fibers (drying, humidifying or dispersing). Some of these steps can be omitted or some other steps may be desirable. The fiber treatment method can be carried out by various means including but not limited to treatments in aqueous or organic solvent solutions, and/or treatments by vacuum or pressure spraying of the sizing agents on dried or wet cellulose fibers.
Percent of Fibers in Slurry
As shown in FIG. 3, in the step of treating pulps in forms of rolls or laps/sheets 302 a and 302 b, emulsified sizing agents are sprayed onto cellulose fibers as shown in steps 304 a and 304b. The sizing reactions may be carried out before, during or after fiberization (individualization) process. In these spraying systems, the sizing agents may be vaporized and the vaporized chemicals may be pressurized to provide enough spraying velocities. Some carrying gases may be used for spraying the sizing chemicals in latex emulsions. Preferably, the nozzles are selected to generate the finest spraying particles possible. It will be appreciated that even for a dry spraying process, the reaction of the sizing agents with the fibers still takes place in the presence of water or an organic solvent due to the composition of the spray itself.
about 10%-80% cement (cementitious binder); about 20%-80% silica (aggregate); about 0%-50% density modifiers; about 0%-10% additives; and about 0.5%-20% sized cellulose fibers or a combination of sized cellulose fibers, and/or regular unsized fibers, and/or natural inorganic fibers, and/or synthetic fibers; The cementitious binder is preferably Portland cement but can also be, but is not limited to, high alumina cement, lime, high phosphate cement, and ground granulated blast furnace slag cement, or mixtures thereof. The aggregate is preferably ground silica sand but can also be, but is not limited to, amorphous silica, micro silica, diatomaceous earth, coal combustion fly and bottom ashes, rice hull ash, blast furnace slag, granulated slag, steel slag, mineral oxides, mineral hydroxides, clays, magnasite or dolomite, metal oxides and hydroxides and polymeric beads, or mixtures thereof.
about 20-50% cement, more preferably about 35%; about 30-70% fine ground silica, more preferably about 60%; about 0-50% density modifiers; about 0-10% additives, more preferably about 5%; and about 0.5-20% fibers, more preferably about 10% fibers, wherein some fraction of the fibers is cellulose fibers sized with sizing agents to increase the hydrophobicity of the fibers. Alternatively, for an air-cured product, a higher percentage of cement can be used, more preferably about 60-90%. In an air-cured embodiment, the fine ground silica is not used, although silica may be used a filler.
As FIG. 4 shows, in step 406, the sized cellulose fibers are proportionally mixed with the other ingredients to form a waterbome mixture, slurry, or paste. The sized fibers are mixed with cement, silica, a density modifier and other additives in a well-known mixing process to form a slurry or paste. In the mixer synthetic fibers can be blended with the sized fibers.
Hatschek sheet process; Mazza pipe process; Magnani process; Injection molding; Extrusion; Hand lay-up; Molding; Casting; Filter pressing; Fourdrinier forming; Multi-wire forming; Gap blade forming; Gap roll/blade forming; Bel-Roll forming; Others. These processes may also include a pressing or embossing operation after the article is formed. More preferably, no pressing is used. The processing steps and parameters used to achieve the final product using a Hatschek process are similar to what is described in Australian Patent No. 515151.
Unbleached Kraft softwood pulp was pre-refined to 500 CSF before the treatment and the refined pulp was used for the sizing treatment. The sized fiber was prepared by treating the refined fiber with alkylsiloxane (Chem-Rex Enviroseal 100) for one hour at 4% of pulp consistency. The dosage of the sizing agent was 10% of the fiber mass and the reaction temperature was ambient under atmospheric pressure. Specimens of fiber cement composite materials were then formed using laboratory apparatus. The formulation for samples A and B, as well as C, D, E, F and G of the following examples are the same: 8% fiber (treated/sized fiber or regular untreated fiber), 35% Portland cement and 57% ground silica. The specimens were air cured for 8 hours at ambient temperature, followed by autoclaving at 180� C. for 12 hours. The physical and mechanical properties of the samples A and B are shown in Table 2.
*Measured after saturating the material in water for more than 48 hours.
**Moisture expansion is the change in product length oven dry to
saturated conditions. The percent change (%) of moisture
expansion is:
*Moisture Expansion was done after 24 hours of carbonation.
**Mechanical tests (MOR, Strain and Toughness Energy) were done under the equilibrium condition of 50+/−5% relative humidity and 23+/−2� C.
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J.2, No. 5; 96-102 (Jun. 1990).58XP002197953 & JP 2001 240458 A, Kamishima Kagaku Kogyo KK) Database WPI, Section Ch, Week 200212, Derwent Publications Ltd., London, GB; AN 2002-085436, Sep. 4, 2001 abstract.* Cited by examinerReferenced byCiting PatentFiling datePublication dateApplicantTitleUS8801901Dec 30, 2013Aug 12, 2014Weyerhaeuser Nr CompanySized fluff pulpEP2707339A4 *May 11, 2012Mar 4, 2015Hardie James Technology Ltd3-mode blended fibers in an engineered cementitious compositeWO2012155103A1 *May 11, 2012Nov 15, 2012James Hardie Technology Limited3-mode blended fibers in an engineered cementitious composite* Cited by examinerClassifications U.S. Classification264/333, 106/731International ClassificationD06M15/55, D06M15/11, D06M101/06, D06M13/192, D06M15/15, C04B40/02, D06M15/227, D06M13/00, D06M23/06, E04C2/04, C04B111/27, C04B16/02, D06M11/57, D06M15/01, D06M13/13, D06M13/513, D06M15/693, D06M13/07, D06M15/263, D06M13/507, B28B3/22, C04B20/10, D21H21/16, C04B28/02, C04B18/24, D21H17/59, B28B3/02, D21H17/13Cooperative ClassificationY02W30/97, Y02W30/94, Y02W30/92, D21H17/13, C04B20/107, C04B20/1051, C04B18/24, C04B2111/2038, C04B28/02, D21H21/16, D21H17/59, C04B18/241, C04B2111/27, C04B2103/65European ClassificationC04B20/10F6, C04B28/02, C04B20/10D, C04B18/24, C04B18/24B, D21H21/16Legal EventsDateCodeEventDescriptionFeb 28, 2005ASAssignmentOwner name: JAMES HARDIE INTERNATIONAL FINANCE B.V., NETHERLANFree format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:JAMES HARDIE RESEARCH PTY LIMITED;REEL/FRAME:016309/0067Effective date: 20050207Owner name: JAMES HARDIE INTERNATIONAL FINANCE B.V.,NETHERLANDFree format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:JAMES HARDIE RESEARCH PTY LIMITED;US-ASSIGNMENT DATABASE UPDATED:20100209;REEL/FRAME:16309/67Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:JAMES HARDIE RESEARCH PTY LIMITED;US-ASSIGNMENT DATABASE UPDATED:20100427;REEL/FRAME:16309/67Free format text: ASSIGNMENT OF ASSIGNORS 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