• 专利附录
  • 专利说明
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    • 专利摘要:
    OUTDOOR COVER PANEL WITH INTEGRATED AIR/WATER BARRIER MEMBRANE. An exterior cladding cementitious panel that prevents water penetration and air leakage is provided. Methods for fabricating cementitious exterior cladding panels with a highly effective integrated air/water barrier membrane are also provided.
    公开号:BR112015020401B1
    申请号:R112015020401-5
    申请日:2014-03-14
    公开日:2021-05-18
    发明作者:Robert H. Negri；Michael P. Shake；Paula McKnight；Paul Shipp；James M. Ullett；Timothy G. Kenny；Brett R. Link；Pamela Hernandez；Kristin Schulte；Dante Marimpietri；Casey Sovey；Muneer Mohammad；Dominic Cremona；Ellen Zerucha；Scottie Lee Stinson
    申请人:Tremco Incorporated；United States Gypsum Company；
    IPC主号:
    专利说明:

    CROSS REFERENCE TO RELATED ORDERS
    [0001] This patent application claims its priority to patent application US 14/198093, which was filed on March 5, 2014 and claims its priority to provisional patent application US 61/792,545, which was filed on March 15, 2013, the entire disclosures of both applications are incorporated into this document by reference. FIELD OF THE INVENTION
    [0002] This invention relates to a building exterior cladding panel with an integrated air/water barrier membrane and methods for fabricating and installing the panel. FUNDAMENTALS
    [0003] The premise of an air/water barrier as part of a building envelope barrier system is to stop the involuntary passage of air, water and other elements into and out of the enveloped building. Exterior air/water barrier foil membranes were first introduced in the industry, but there are several problems associated with installing foils in the field because seams are such critical joints. Installation of blades does not always coincide with the instructions provided by the manufacturer. Environmental conditions (eg wind, temperature, rain, etc.) can create significant obstacles to the successful installation of sheet materials. In addition, the foil liner usually provides a poor bonding surface for other building materials, thereby making the foils difficult to adhere to.
    [0004] Fluid-applied air/water barrier membranes are newer to the industry and are gaining acceptance as an alternative to blade membrane barrier products. Applied barrier fluid-membrane products are quicker to install than sheet membrane barrier products at the job site. Typical installation staffing requirements are less than with membrane-to-blade barrier installations. Applied membrane fluids are typically applied by spraying on the job site, which significantly increases the production rate compared to the application of sheet membranes. However, application issues can occur, such as an incorrect amount of material being applied due to applicator error, equipment issues and/or environmental conditions (eg wind, temperature, rain, etc.). Such issues not only impact the quality and durability of the air/water barrier installation, but can also incur significant additional costs to clean and repair damage to adjacent buildings and cars due to overspray.
    [0005] Conventional methods for installing the outer cladding, air barrier and water resistant barrier require separate teams who carry out the installation around the perimeter of the building in several steps: to install the first cladding, then finish the joints in the second round and then install the water resistant barrier and the air barrier in the next separate round.
    [0006] Accordingly, there continues to be a need to provide an air/water barrier membrane that minimizes problems associated with the installation. There also continues to be a need to build panels coated with an air/water barrier membrane under controlled conditions during manufacturing.
    [0007] It will be appreciated that this description of fundamentals was created by the inventors to assist the reader, and should not be taken as an indication that any of the problems indicated themselves were appreciated in the art. While the principles described may, in some respects and modalities, alleviate problems inherent in other systems, it will be appreciated that the scope of the protected innovation is defined by the appended claims and not by the ability of any disclosed resource to solve any specific problem mentioned herein. ABSTRACT
    [0008] In one aspect, the present disclosure is directed to modalities of a cementitious building panel that prevents water penetration and air leakage.
    [0009] One embodiment is directed to a cementitious panel comprising a cementitious core, at least one cover sheet and an integrated air/water barrier membrane. In the panel, a cover sheet is sandwiched between the cementitious core and the integrated air/water barrier membrane. The cementitious core may comprise a calcium sulfate material, Portland cement or a combination of the two. The panel may include a second covering lamina and in this embodiment, a cementitious core is sandwiched between the first covering lamina and the second covering lamina, and the first covering lamina is sandwiched between the cementitious core and the air barrier membrane /integrated water.
    [0010] In some embodiments, the cementitious panel includes a paper sheet or a fibrous mat as a covering sheet. Various fibers can be used in the mat, including, without limitation, polymeric and mineral fibers.
    [0011] In some embodiments, an exterior cladding panel comprises an integrated air/water barrier membrane that includes from 30 to 70% by weight of a polymeric binder selected from the group consisting of a polyacrylate, polyurethane, silicone emulsion , polystyrene, styrene acrylic copolymers and combinations thereof and from 20 to 50% by weight of calcium carbonate. The integrated air/water barrier membrane may additionally include at least one of the following: a dispersant, defoamer, pigment, thickener, preservative, pH regulator, emulsion stabilizer, wetting and leveling agent, crosslinker, and combinations thereof .
    [0012] Additional modalities include an outer cladding panel in which an integrated air/water barrier membrane has a dry thickness in the range of 0.254 to 2.286 mm (10 to 90 mils).
    [0013] In some embodiments, an antimicrobial/antifungal agent is added to a cementitious core, a cover sheet and/or an integrated air/water membrane. Suitable antimicrobial agents include 2-(4-thiazolyl)benzimidazole, silver zeolite, zinc oxide and zinc pyrithione.
    [0014] Additional modalities provide an in-factory method for fabricating an exterior cladding panel with an integrated air/water barrier membrane. The method comprises preparing a slurry with a cementitious material; sandwich the slurry between two cover sheets; allowing the slurry to harden and form a cementitious panel; spray coating the cementitious panel on at least one surface with an integrated air/water barrier membrane formulated with a polymeric binder and calcium carbonate; and conditioning the spray coated cementitious panel in an oven, wherein the panel is exposed to at least two different temperature zones. BRIEF DESCRIPTION OF THE FIGURES FIG. 1 is a fragmentary cross-section of the present outer cladding panel with an integrated air/water barrier membrane; and FIG. 2 depicts a control panel in Fig. 2A and the present outer cladding panel with an integrated air/water barrier membrane obtained by the method presented in Fig. 2B. DETAILED DESCRIPTION
    [0015] The present disclosure provides various embodiments of an exterior cladding panel that is physically integrated with an air/water barrier membrane to provide a single barrier component. An integrated air/water barrier membrane cladding panel can provide a single, easy-to-install panel that eliminates the need to individually install separate air and water resistant barriers at the job site. In doing so, the number of steps required to complete the construction casing is reduced and the number of joints that must be individually sealed is reduced, substantially reducing the time and labor required to meet the performance requirements of a barrier system. air/water for a building enclosure. This disclosure also provides modalities related to methods in which exterior cladding panels with air/water barrier membranes are mass-produced with uniform and monolithic barrier properties in a controlled factory environment, thereby reducing problems associated with having an amount insufficient barrier material applied in the field. Additionally, applying the air/water barrier membrane to the outer coating in a controlled automated factory configuration, as provided in this disclosure, ensures that the membrane application is not subject to vicissitudes of climate/environment variability or worker fatigue providing, thereby a consistent coating thickness with ideal adhesion bond between the air/water barrier membrane and the coating substrate.
    [0016] In particular, in some embodiments, an exterior cementitious cladding panel comprises an air/fluid water barrier adhesively applied to at least one surface of the panel. Referring to FIG. 1, some embodiments include an outer cladding panel with an integrated air/water barrier membrane, generally designated 10. The panel includes a cementitious core 12; a cover lamina 14a, an optional cover lamina 14b and an air/water barrier membrane 16. The cementitious core 12 is sandwiched between cover lamina 14a and 14b. The covering lamina 14a is overlaid with the air/water barrier membrane 16 such that the covering lamina 14a is sandwiched between the cementitious core 12 and the integrated air/water barrier membrane 16.
    [0017] A cementitious cladding panel can be composed of any suitable inorganic core material intended for exterior applications. In particular, the core can be composed of any cementitious material, substance or composition, together with any suitable additives. Non-limiting examples of materials that can be used in the cementitious core include: Portland cement; sorrel cement; slag cement; fly ash cement; calcium alumina cement; water-soluble calcium sulfate anhydrite; α-calcium sulfate semihydrate; β-semihydrate calcium sulfate; natural, synthetic or chemically modified calcium sulfate semihydrate; calcium sulfate dihydrate ("gypsum", "hardened gypsum", or "hydrated gypsum"); and mixtures thereof. As used herein, the term "calcium sulfate material" refers to any of the forms of calcium sulfate referenced above. In certain preferred embodiments, the cementitious core comprises a calcium sulfate material, Portland cement or a mixture thereof. Preferably, the cementitious core comprises gypsum.
    [0018] Examples of cementitious exterior cladding panels suitable for use in embodiments of the present disclosure include, for example, those commercially available from United States Gypsum, Chicago, IL, under the trade names SHEETROCK®, SHEETROCK FIRECODE®, SECUROCK® , FIBEROCK® and DUROCK®.
    [0019] The cementitious core may comprise additives such as any additives commonly used to produce cementitious articles (eg gypsum board or cement board). Suitable additives include, without limitation, structural additives such as mineral wool, continuous or chopped glass fibers (also referred to as fiberglass), perlite, clay, vermiculite, calcium carbonate, polyester and paper fiber. Chemical additives include, for example, foaming agents, fillers, accelerators, sugar, enhancing agents (eg phosphates, phosphonates, borates), retarders, binders (eg starch and latex), colorants, fungicides and biocides. Examples of the use of some of these and other additives are described, for example, in U.S. Patent No. 6,342,284; 6,410.118; 6,632,550; 6,800,131; 5,643,510; 5,714,001; and 6,774,146 and U.S. Patent Application Publication No. 2004/0231916; 2002/0045074; and 2005/0019618, the disclosures of which are hereby incorporated herein by reference. In certain embodiments, the cementitious core additionally comprises metallic fibers, cellulose fibers, mineral fibers, glass fibers, polymer fibers, carbon fibers or a combination thereof.
    [0020] The cementitious core is covered on at least one substrate and in some embodiments by two substrates, superimposed relative to the core on opposite faces thereof. In other words, the cementitious core is sandwiched between two substrates. The substrate can be a cover sheet, such as a paper cover sheet or a mat, for example. Various types of paper cover sheets are known in the art (e.g. shackle, kraft, polymer, etc.) and all such types of paper cover sheets can be used in the present invention. Multilayered papers can be used in various modalities. If desired, the paper cover sheet can be treated with a chemical or physical additive to impart a property, such as waterproof, fireproof, antifungal, and/or antimicrobial properties. In some embodiments, the cover sheet is a paper cover sheet having a weight of from about 40 to about 65 lb/msf (thousands of square feet).
    [0021] In other embodiments, cover sheets comprising fibrous mats are used. The mat can comprise any suitable type of polymer fiber, mineral fiber or combination thereof. Non-limiting examples of suitable fibers include glass fibers, polyamide fibers, polyaramid fibers, polypropylene fibers, polyester fibers (eg polyethylene terephthalate (PET)), polyvinyl alcohol (PVOH), polyvinyl acetate (PVAc), fibers cellulosics (eg cotton, rayon, etc.) and combinations thereof. In addition, mat fibers can be hydrophobic or hydrophilic, coated or uncoated. The choice of fibers will depend, in part, on the type of application in which the cementitious cladding board is to be used. For example, when cladding board is used for applications that require heat or fire resistance, suitable heat or fire resistant fibers must be used in the fibrous mat.
    [0022] The fibrous mat can be woven or non-woven. Non-woven mats comprise fibers bonded together by a binder. The binder can be any binder commonly used in the belt industry. Suitable binders include, without limitation, urea formaldehyde, melamine formaldehyde, melamine formaldehyde stearate, polyester, acrylics, polyvinyl acetate, urea formaldehyde or melamine formaldehyde modified or blended with polyvinyl acetate or acrylic, styrene acrylic polymers and combinations thereof. Suitable fibrous mats include commercially available mats used as cladding materials for cementitious exterior cladding panels.
    [0023] The integrated panel can be prepared by any suitable method. In general, an applied air/water barrier adhesive fluid is applied to at least one surface (e.g., the outer skin surface) of a cementitious outer skin panel. The adhesive fluid can be any suitable composition and is in the form of a liquid polymer formulation in some embodiments. An application step can comprise any suitable method of adding the liquid polymer formulation to a surface of the cladding panel. Such methods are known in the art and include, for example, spraying, rolling (e.g. pressure rolling), troweling, brushing, scraping, dipping, soaking and/or impregnating the panel surface with the liquid polymer formulation. Once applied, the liquid polymer formulation dries, solidifies, hardens and/or cures on the surface to provide an adhesive layer that has air and/or moisture proof properties. This step can be performed at room temperature or at an elevated temperature for a specified period of time to achieve the desired level of adhesion.
    [0024] The liquid polymer formulation can be any suitable material used in applied fluid-membranes. A formulation suitable for an air/water barrier formulation must meet or exceed the minimum requirements set forth by CAN/ULC-S741 ("Standard for Air Barrier Materials - Specification") and tested in accordance with ASTM E2178 ("Method of Standard Test for Air Permeability of Building Materials"). Such formulations include those that prevent or minimize air infiltration/exfiltration and water penetration through an outer cladding panel with an integrated air/water barrier membrane, while the panel still remains permeable to water vapor. Other suitable air/water barrier formulations include those that prevent or minimize air infiltration/exfiltration through the panel and also minimize the panel's permeability to water vapor.
    [0025] In at least some embodiments, after drying and/or curing, the liquid polymer formulation forms a rubberized (elastomeric) membrane on at least one surface of an outer cladding panel.
    [0026] At least in some embodiments, the liquid polymer formulation comprises one or more materials (eg polymers) that serve as a polymer binder and provide a self-sealing effect after the formulation has dried and/or cured. Non-limiting examples of liquid polymer formulation suitable for an exterior cladding panel with an integrated air/water barrier membrane include polyacrylate (e.g. polymers and copolymers based on methacrylate, ethyl acrylate, ethyl methylacrylate, butylacrylate, methacrylate of butyl, 2-chloroethylvinyl ether, 2-ethylhexyl acrylate and hydroxyethyl methacrylate), polystyrene, polybutadiene, poly(butadiene co-styrene), polyisoprene, polyacrylonitrile butadiene, polychloroprene, polyvinyl acetate, polyvinyl chloride, polyurethane, acetate polyvinyl, silicone emulsion and combinations thereof. Examples of applied fluid-membranes are exemplified by, for example, U.S. Patent Nos. 8,151,537 and 7,662,221, the disclosures of which are hereby incorporated by reference herein.
    [0027] In certain embodiments, the liquid polymer formulation is in the form of a liquid emulsion (eg, a liquid polymer emulsion), such as a water-based elastomeric emulsion (eg, a water-based acrylic emulsion ) or an oil-based elastomeric emulsion (eg a rubberized (elastomeric) emulsion). Solvents used in the emulsion can be water, organic solvent or a combination of these. Examples of organic solvent include turpentine, mineral oil, xylene and naphtha.
    [0028] At least in some embodiments, an outer cladding panel with an integrated air/water barrier membrane comprises a membrane that has been prepared from a formulation comprising an acrylic emulsion. In at least some embodiments, an outer skin panel with an integrated air/water barrier membrane comprises a membrane with 5 to 80% by weight of a polyacrylate. In at least some embodiments, an outer cladding panel with an integrated air/water barrier membrane comprises a membrane with 30 to 70% by weight of a polyacrylate. In at least some embodiments, an outer cladding panel with an integrated air/water barrier membrane comprises a membrane with 40 to 60% by weight of a polyacrylate.
    [0029] At least in some embodiments, an outer cladding panel with an integrated air/water barrier membrane comprises a membrane prepared from a formulation comprising polyurethane. In at least some embodiments, an outer cladding panel with an integrated air/water barrier membrane comprises a membrane comprising from 5 to 50% by weight of polyurethane. In at least some embodiments, an outer cladding panel with an integrated air/water barrier membrane comprises a membrane comprising from 10 to 40% by weight of polyurethane. In at least some embodiments, an exterior cladding panel with an integrated air/water barrier membrane comprises a membrane comprising a combination of polyurethane with another polymer selected from at least one of the following, silicone and a polyacrylate. In at least some embodiments, an outer skin panel with an integrated air/water barrier membrane comprises a membrane comprising a styrene copolymer.
    Preferred polymeric binders for an air/water barrier membrane integrated into an outer cladding panel have been found to include acrylic latex, styrene acrylic copolymers and styrene-butadiene dispersions. These polymeric binders can be used in the amount of 30 to 70%. In some embodiments, a polymeric binder may be selected from the following commercially available binders: PLIOTEC EL-25 (Acrylic Elastomeric Latex) from Omnova, ACRONAL S400 (Aqueous Dispersion of Copolymer Free of Plasticizers of Acrylic Acid Ester and Styrene) from BASF, UCAR 9176 (Styrene Acrylic Copolymer) from DOW, RHOPLEX 2620 (100% Acrylic Polymer) from DOW or BUTONAL NS 175 (High Solids, Cold Polymerized Anionic Styrene-Butadiene Dispersion) from BASF.
    [0031] In some embodiments, an outer cladding panel with an integrated air/water barrier membrane comprises a membrane that has been prepared from a formulation comprising a polymer emulsion and a dispersant. Various dispersants can be used to stabilize the emulsion, such as polyvinyl alcohols, cellulose and derivatives thereof, copolymers containing vinylpyrrolidone, ethoxylated mono, di and trialkylphenols, ethoxylated fatty alcohols and alkali metals and ammonium salts of sulfuric acid alkyl sulfates, monoesters of ethoxylated alkanols and ethoxylated alkylphenols of alkylsulfonic acids and of alkylarylsulfonic acids, the alkali metals and/or ammonium salts of dodecylbenzenesulfonic acid and the alkali metals and/or ammonium salts of ethoxylated dodecanol sulfuric acid monoester. Dispersants can be added to the formulation in an amount of about 0-10% by weight (for example, between about 1-9% by weight, between about 2-7% by weight, between about 3-6% by weight) .
    [0032] In some embodiments, a suitable dispersant includes solution of a high molecular weight block copolymer with pigment affinic groups, solution of an ammonium salt of an acrylate copolymer, anionic polyelectrolyte, potassium tripolyphosphate, and alkylol ammonium salt of a copolymer with acidic groups. These dispersants can be used in the amount of 0-10% and preferably 0.1-5%. In some embodiments, a dispersant can be selected from the following commercially available dispersants: DISPERBYK-190 (solution of a high molecular weight block copolymer with pigment affinic groups) from BYK, BYK-156 (solution of a salt of ammonium from an acrylate copolymer) from BYK, TAMOL 851 (anionic polyelectrolyte) from DOW, Potassium tripolyphosphate (triphosphoric acid, pentapotassium salt) from INNOPHOS, DISPERBYK-180 (an alkylol ammonium salt of a copolymer with acid groups) from BYK.
    [0033] In some embodiments, an exterior cladding panel with an integrated air/water barrier membrane comprises a membrane formulated with one or more additives to further enhance the performance of the barrier material. Suitable additives include, for example, petroleum asphalt, limestone, calcium carbonate, a silane (for example, diaminosilane, trimethoxy vinylsilane), a glycol (for example, ethylene glycol, propylene glycol, dipropylene glycol monobutyl ether), a tacifier ( for example, a calaphony or calaphony derivative, such as wood calaphony, a terpene or modified terpene, an aliphatic, cycloaliphatic or aromatic resin), an adhesion promoter, a cure catalyst, a crosslinking agent, a termiteicide, a fungus growth inhibiting agent (eg 2-(4-thiazolyl) benzimidazole, silver zeolite, zinc oxide and zinc pyrithione), a filler (eg kaolin clay, mica, heavy spar, talc, sand , quartz flour, chalk, titanium dioxide, silica, fly ash), and/or a phase change material.
    [0034] In some embodiments, an exterior cladding panel with an integrated air/water barrier membrane comprises a membrane formulated with a polymeric binder described above and calcium carbonate, which can be used in the amount of 20 to 50% by weight . Suitable commercial sources of calcium carbonate include, but are not limited to, THIXO-CARB 500TM (Precipitated Calcium Carbonate) from Specialty Minerals, ULTRAFLEX 100TM (Precipitated Calcium Carbonate) from Specialty Minerals, HUBERCARB Q6TM (Precipitated Calcium Carbonate) Calcium) from Huber Engineered Materials, OMYACARB 100-PTTM (Calcium Carbonate) from Omya, HUBERCARB Q325TM (Calcium Carbonate) from Huber Engineered Materials and NEOLIGHT SSTM (Precipitated Calcium Carbonate) from Takehara Kagaku Kogyo Co.
    [0035] In some embodiments, an exterior cladding panel with an integrated air/water barrier membrane comprises a membrane formulated with a polymeric binder as described above, calcium carbonate and at least one or more additives, such as a defoamer, pigment, thickener, preservative, pH regulator, emulsion stabilizer, wetting and leveling agent and crosslinker.
    [0036] In some embodiments, suitable defoamers include, but are not limited to a mixture of paraffinic mineral oils and hydrophobic components, composite molecules in a reinforced mineral oil system, a solution of a polyether-modified polydimethylsiloxane and a mixture of polysiloxanes and hydrophobic solids in polyglycol. These defoamers can be used in the amount of 0.1 to 5%. Suitable commercial sources for a defoamer include BYK-033TM (mixture of paraffinic mineral oils and hydrophobic components) from BYK, FOAMSTAR ST 2410TM, also known as FOAMSTAR A10TM (compound molecule in a reinforced mineral oil system) from BASF, BYK-019TM (solution of a polyether-modified polydimethylsiloxane) from BYK, BYK-021TM (mixture of foam destroying polysiloxanes and hydrophobic solids in polyglycol) from BYK.
    [0037] In some embodiments, suitable pigments include, but are not limited to, titanium dioxide, zinc oxide, carbon black, micronized precipitated silica, talc and combinations thereof. These pigments can be used in the amount of 0.1% to 10% by weight. Suitable commercial sources for a pigment include HUNTSMAN TR93TM (Titanium Dioxide) from Maroon Inc., ZOCO 101TM (Zinc Oxide) from Zochem Icc., SOLTEX ACE BLACKTM (Carbon Black) from Soltex, ZEOTHIX 265TM (Micronized Precipitated Silica) from Huber and SIERRALITE 402STM (Talc) from Imerys.
    [0038] In some embodiments, suitable thickeners include, but are not limited to, at least one of the following: hydroxyethylcellulose, acrylic thickener, anionic inverse emulsion thickener, HASE, and hydrophobically modified alkaline swellable acrylic emulsion. These thickeners can be used in the amount of 0.1% to 5% by weight. Suitable commercial sources for a thickener include NATROSOL 250 HBRTM (Hydroxyethylcellulose) from Ashland Inc., ACRYSOL ASE-95NPTM (Soluble Alkaline, Acrylic Thickener) from DOW, TEXIPOL 63-510TM (Anionic Inverse Emulsion Thickener) from Scott Bader, POLYPHOBE 106HETM (HASE) from Arkema and SOLTHIX A100TM (Hydrophobically Modified Alkaline Expandable Acrylic Emulsion) from Lubrizol.
    [0039] In some embodiments suitable preservatives include, but are not limited to, at least one of the following: 2[(Hydroxymethyl)amino]-2-methylpropanol, 3-iodo-2-propynyl-butyl carbamate, n-( 3,4-Dichlorophenyl)-n,n-Dimethylurea, 1,2-benzisothiazolin-3-one and tetrachloroisophthalonitrile. These thickeners can be used in the amount of 0.1% to 5% by weight. Suitable commercial sources for a thickener include TROYSAN 186TM (2[(Hydroxymethyl)amino]-2-methylpropanol) from Troy Corporation, POLYPHASE AF1TM (3-iodo-2-propynyl-butyl carbamate) from Troy Corporation, POLYPHASE 663TM (n-(3,4-Dichlorophenyl)-n,n-Dimethylurea) from Troy Corporation, MERGAL 758TM (1.2 benzisothiazolin-3-one) from Troy Corporation and NUOCIDE 404DTM (Tetrachloroisophthalonitrile) from Ashland Inc.
    [0040] In some embodiments, suitable pH regulators include, but are not limited to, at least one of the following: calcium hydroxide, sodium hydroxide, potassium hydroxide, 30% aqueous ammonia, and 2-Amino-2- methyl-1-propanol. These pH regulators can be used in the amount of 0.1% to 5% by weight. Suitable commercial sources for a pH regulator include Calcium Hydroxide (Calcium Hydroxide) from Jost Chemical, Caustic Soda (Sodium Hydroxide Solution) from OXYChem, Potassium Hydroxide (Potassium Hydroxide) from Chem One Ltd., Ammonia Hydroxide Solution (30% Aqueous Ammonia) from Tanner Industries and AMP 95 (2-Amino-2-methyl-1-propanol) from Angus.
    [0041] In some embodiments suitable emulsion stabilizers include, but are not limited to, at least one of the following: bentonite clay, a high molecular weight crosslinked copolymer of acrylic acid and C10-C30 alkyl acrylate, ethoxylated octylphenol surfactant non-ionic, TALL OIL resin extract and natural resin. These emulsion stabilizers can be used in the amount of 0.1% to 5% by weight. Suitable commercial sources for an emulsion stabilizer include OPTIGEL LXTM (Bentonite Clay) from BYK, PEMUIEN 1622TM (a high molecular weight, cross-linked copolymer of acrylic acid and C10-C30 alkyl acrylate) from Lubrizol, TRITON X405TM (no ionic, octylphenol ethoxylate surfactant) from DOW Chemical Company, SYLVAROS™ NCY (TALL OIL Resin) from Arizona Chemical and VINSOLTM SOAP (Natural Resin extract) Pinnova.
    [0042] In some embodiments, wetting and leveling agents include, but are not limited to, at least one of the following: sulfosuccinate, polyether-modified siloxane, urea-modified polyurethane, urea-modified ammonium salt of an acrylate copolymer . These wetting and leveling agents can be used in the amount of 0.1% to 5% by weight. Suitable commercial sources for a wetting and leveling agent include AEROSOLTM LF-4 (Proprietary Sulfosuccinate Blend) from Cytec, BYK-349 (Polyether Modified Siloxane), BYK-425 (Urea Modified Polyurethane), BYK-420 ( Modified by Urea) and BYK-154 (Ammonium Salt of an Acrylate Copolymer) from BYK.
    [0043] In some embodiments, suitable crosslinkers include, but are not limited to, at least one of the following: zinc oxide, zinc metal ions, anionic hydroxylated zirconium polymers containing ammonium stabilized zirconium carbonate and epoxy functional silane. These crosslinkers can be used in the amount of 0.1% to 5% by weight. Suitable commercial sources for a crosslinker include Zinc Oxide (Zinc Oxide) from US Zinc, ZIMPLEXTM 15 (Zinc Metal Ions) from Munzing, BACOTETM 20 (Clear Alkaline Ammonium Stabilized Zirconium Carbonate Solution, Containing anionic hydroxylated zirconium polymers) from Melchemical Inc., OXYLINKTM 3404 (aqueous formulation of inorganic particles including zinc oxide) from Buhler Group and SILANETM A-187 (Epoxy silane functional) from Momentive.
    [0044] In some embodiments, an exterior cladding panel with an integrated air/water barrier membrane comprises a membrane formulated with a suitable polymer as described above and at least one of the following additives: petroleum asphalt, limestone, carbonate calcium, kaolin clay, mica, heavy spar, talc, sand, quartz flour, chalk, titanium dioxide, silica, fly ash, gypsum or a combination of at least two of these additives. Additives can be used in different amounts, including 20 to 80% by weight; from 25 to 75% by weight and from 30 to 60% by weight. In some embodiments, an exterior cladding panel with an integrated air/water barrier membrane comprises a membrane formulated with a polyacrylate and at least one of the following additives: petroleum asphalt, limestone, calcium carbonate, kaolin clay, mica , heavy spar, talc, sand, quartz flour, chalk, titanium dioxide, silica, fly ash, gypsum or a combination of at least two of these additives.
    [0045] In some embodiments, an exterior cladding panel with an integrated air/water barrier membrane comprises a membrane formulated with an antimicrobial and antifungal agent selected from 2-(4-thiazolyl) benzimidazole, silver zeolite , zinc oxide and zinc pyrithione. An antimicrobial/antifungal agent can be used in various amounts, including from about 1 to about 10% by weight, or about 3 to about 7% by weight.
    [0046] In some embodiments, an outer cladding panel with an integrated air/water barrier membrane comprises a membrane comprising a pigment. Various pigments can be used, including chemical compounds that provide a black, brown, blue, green, red, yellow, orange or white pigment.
    [0047] Examples of commercially available applied air/water barrier fluids include those marketed under the trade names: EXOAIR™ (Tremco), TYVEK™ (DuPont), R-GUARD™ (Prosoco), AIRSHIELD™ (WR Meadows), STOGUARD™ (Sto Corp.) and AIR BLOC™ (Henry Co.).
    [0048] In some embodiments, an exterior cladding panel with an integrated air/water barrier membrane comprises a membrane formulated with a polymer binder, calcium carbonate and other components provided in Table 1 below.




    [0049] In some embodiments, an exterior cladding panel with an integrated air/water barrier membrane is manufactured by a method that controls the thickness of the integrated air/water barrier membrane. The thickness can be controlled such that an outer cladding panel with an integrated air/water barrier membrane significantly reduces air infiltration/exfiltration and water penetration through the panel. Some embodiments provide an outer cladding panel with an integrated air/water barrier membrane that reduces air infiltration/exfiltration and water penetration through the panel by at least 50%. Some other embodiments provide an outer cladding panel with an integrated air/water barrier membrane which reduces air infiltration/exfiltration and water penetration through the panel by at least 70-80%. Exterior cladding panels with an integrated air/water barrier membrane that sufficiently reduce air infiltration/exfiltration and water penetration include those panels where a dry thickness of the integrated air/water barrier membrane is at least 0.254 mm ( 10 mils), at least 0.508 mm (20 mils), at least 0.762 mm (30 mils), at least 1.016 mm (40 mils), at least 1.270 mm (50 mils), at least 1.524 mm (60 mils), at least minus 1.778 mm (70 mils); and less than 2,540 mm (100 mils), less than 2.286 mm (90 mils), less than 2,032 mm (80 mils), less than 1.778 mm (70 mils), less than 1.524 mm (60 mils), less than 1.270 mm (50 mils), less than 1.016 mm (40 mils). The above values can be combined in any suitable range using the upper and lower values, for example, 0.254-2.286 mm (10-90 mils), 0.508-2.032 mm (20-80 mils), 1.016-2.032 mm (40-80 mils), 1,5242,032 mm (60-80 mils), etc.
    [0050] In order to obtain an outer cladding panel with an integrated air/water barrier membrane, the membrane formulation can be applied to the panel in a thickness of 0.127-2.540 mm (5-100 mils) (eg. at least 0.127 mm (5 mils), at least 0.254 mm (10 mils), at least 0.508 mm (20 mils), at least 0.762 mm (30 mils), at least 1.016 mm (40 mils), at least 1.270 mm ( 50 mils), at least 1.524 mm (60 mils), at least 1.778 mm (70 mils); and less than 2.540 mm (100 mils), less than 2.286 mm (90 mils), less than 2.032 mm (80 mils), less than 1.778 mm (70 mils), less than 1.524 mm (60 mils), less than 1.270 mm (50 mils), less than 1.016 mm (40 mils)). The above values can be combined in any suitable range using the upper and lower values, for example, 0.254-2.286 mm (10-90 mils), 0.508-2.032 mm (20-80 mils), 1.016-2.032 mm (40-80 mils), 1.524-2.032 mm (60-80 mils), etc. Since the membrane (eg liquid polymer formulation) is normally applied as an emulsion, the initial layer is "wetted". As the membrane dries, the thickness of the membrane layer will shrink depending on the concentration of the formulation. Therefore, the dry thickness will be reduced in size from the initial wetted thickness by an amount of about 10% or more (for example, about 20% or more, about 30% or more, about 40% or more, about 50%).
    [0051] In one embodiment, a cementitious outer cladding panel with an air/water barrier membrane integrated in at least one surface, as described above, further comprises a foil membrane adhered to the integrated air/water barrier membrane. After the integrated air/water barrier membrane is formed in the panel, a foil membrane with air and/or moisture resistant properties can be applied to the membrane. The foil membrane can be applied to the integrated air/water barrier membrane using any suitable method such as hardening, rolling, laminating, calendering and/or pressing. Normally, the foil membrane will be cut to size proportionate with the cementitious outer cladding panel. The foil can generally be cut prior to application to the panel, but in some embodiments, the foil membrane is applied in roll form to a series of joined panels, which can then be cut to define single integrated panels.
    [0052] In some embodiments, the integrated air/water barrier membrane typically has a sufficiently adhesive characteristic to secure the membrane to foil without additional adhesive(s).
    [0053] In some embodiments, a system for installing an outer cladding panel with an integrated air/water barrier membrane is provided. Such a system can include one or more supplemental adhesive/sealant coatings that can be applied to the integrated air/water barrier membrane of the outer skin panel. Additional adhesive can be applied over the entire surface of the panel or on selected areas of the surface (eg perimeter, center, parallel edges, etc.). An additional adhesive can be of any suitable material, such as those marketed under the trade names: EXOAIR™ (Tremco), TYVEK™ (DuPont), R-GUARD™ (Prosoco), AIRSHIELD™ (WR Meadows), STOGUARD™ (Sto Corp.) and AIR BLOC™ (Henry Co.). In some embodiments, suitable sealants include a polyurethane based sealant such as SPECTREM 1™ (Tremco) and a silicone based sealant such as DYMONIC 100™ (Tremco). In at least some embodiments, an installation system includes an outer cladding panel with an air/water barrier membrane and at least one polyurethane-based and/or silicone-based sealant.
    [0054] While in some embodiments an outer cladding panel with an integrated air/water barrier membrane can be used in combination with a supplementary sheet membrane, in other embodiments the outer cladding panel can be used without the membrane in blade. The foil membrane with air and/or moisture resistant properties (also known as house or building wrapping) can be any suitable material, such as those prepared from asphalt-impregnated paper or fiberglass, cross-coating films microperforated, continuous filament nonwoven laminated films, polypropylene laminated or coated woven films, polyolefin fibril nonwoven (eg polyethylene) super wet calendered (eg TYVEK™), and drainable house wraps. In embodiments, a suitable foil membrane may meet or exceed the minimum requirements set forth by ASTM E2178 ("Standard Test Method for Air Permeability of Building Materials"). Examples of blade construction casings are shown and described in U.S. Patent No. 7,148,160 and U.S. Patent Application Publication Nos. 2006/0040091 and 2006/0051560, for example, the disclosures of which are hereby incorporated by reference herein. Examples of commercially available foil membranes include those marketed under the following trade names: Tri-Built Building Wrap (Tri-Built), TYVEK™ (DuPont), HARDIEWRAP™ (James Hardie), HYDROGAP™ (Benjamin Obdyke), WEATHERMATE™ ( Dow), BLUESKIN™ (Henry Co.), FOILSKIN™ (Henry Co.), AIRSHIELD™ (WR Meadows) and CERTAWRAP™ (CertainTeed).
    [0055] The integrated air/water barrier membrane, optionally in combination with a sheet membrane, enables the panel system (cementitious panel, integrated air/water barrier membrane and optionally sheet membrane) with the versatile capability adjust and/or change the panel's water vapor permeability rate. The ability to adjust the water vapor permeability rate of an air and moisture resistant cementitious outer cladding panel while retaining a consistent panel thickness is particularly beneficial, depending on the designed and/or intended performance of the outer construction casing. Based on a particular set of building science design principles relating to moisture management in wall mounts and/or the geographic and climatic region of use, the air and moisture resistant cementitious exterior cladding panel may need to be manufactured having different water vapor permeability rates to meet building energy performance requirements and/or projected building shell performance. For example, the US Department of Energy describes seven (7) climate zones. Each of the seven zones is based on the measurement of temperature hold days (HDD) and cool temperature days (CDD). These metrics are used to rate how severe the heating and cooling conditions are for buildings in different regions of the country. For example, Climate Zone 1 (South Florida) has CDD >9000 and building space conditioning is entirely dominated by cooling down. On the other hand, in an area similar to the upper Midwest located in Climate Zone 6, construction energy use is dominated when heating loads, with HDD greater than 7200 and less than 9000. Humidity and water conditions should also be considered during the design process. Moisture considerations have a major impact on optimizing energy systems within the housing, often dictating which materials or systems work best in terms of both energy performance and moisture control. For example, in hot, dry climates, evaporative cooling systems can provide space cooling for homes; typically using less energy than traditional vapor compression A/C systems. However, in areas similar to the hot/wet Southeast, special attention must be paid to the vapor permeability of exterior wall mounts to avoid serious moisture and mold problems in the building casing. Therefore, the need for different water vapor permeability rates related to air and moisture proof cementitious outer cladding panels is of importance.
    [0056] The water vapor permeability rate can be modified by adjusting the amount of the integrated air/water barrier membrane applied and/or by adjusting the projected water vapor permeability rate of the optional constructed sheet membrane which does not change in thickness while at the same time it may be intentionally constructed having different water vapor permeability rates. An exemplary method to modify and/or adjust the projected water vapor permeability rate of the air and moisture proof cementitious outer cladding panel would be to provide a panel that remains dimensionally consistent in thickness. In practical applications, where a consistent panel thickness is desired, but different water vapor permeability rates desired, the integrated air/water barrier membrane would remain fixed and the optional sheet membrane water vapor permeability rate changed to achieve a wide range of air and moisture resistant cementitious outer cladding panel types classified by water vapor permeability. The foil membrane also prevents the integrated panels from sticking (locking) together.
    [0057] In another embodiment, a cementitious cladding panel comprises an air/water barrier membrane integrated into at least one surface of the panel and an insulating material that is at least partially incorporated into the membrane. Insulating material is any suitable material that can be incorporated into the integrated air/water barrier membrane to prevent the integrated panels from sticking (blocking) together. Due to the rubbery nature of the membrane, the surface can remain tacky even after drying and/or curing. As a result, an insulating material that physically prevents adjacent embedded panels from coming into contact with each other can be used to prevent adhesion and/or damage to the embedded panels.
    [0058] In one embodiment, the insulating material is an open weft mesh. The mesh is prepared from any suitable material. For example, the mesh may comprise a natural or synthetic material (e.g. fiber), such as cotton, jute, sisal, wool, hemp, linen fiber, bamboo, linen, glass, metal, nylon, polyethylene, polypropylene, acrylic , polyester, carbon fiber and combinations thereof. If desired, the mesh material can have certain properties, such as fire resistance, mildew resistance, water resistance and/or alkaline resistance, which are either intrinsic to the material or the result of a chemical additive and/or treatment.
    [0059] To provide an anti-blocking property, the mesh must be of a thickness greater than the dry thickness of the membrane. The diameter of the mesh filaments can be selected such that a portion of the mesh extends beyond the surface of the dry membrane. The size (tightness) of the weft is not particularly limited, but to save cost, the spacing between the mesh filaments can range from about 1 to 1.5 inches (about 2.54 to 3.81 cm). A more open weft also ensures that the mesh does not interfere with the self-sealing effect provided by the membrane in relation to fasteners used during installation of the integrated panel.
    [0060] The mesh is preferably applied as a sheet that is proportional to the size of the integrated panel. The mesh can be applied at any desirable stage to the membrane. For example, the membrane can be fully wetted, partially dried or fully dried, as long as the membrane retains an adequate amount of adhesion to allow the mesh to incorporate and be maintained.
    [0061] In another embodiment, the insulating material is a pellet or granule that is at least partially incorporated into the membrane. The pellet or granule is any suitable material that provides an anti-blocking effect. The only real limitations are that the pellets or granules are made of a durable material and have a size (ie diameter or thickness) that is greater than the thickness of the dry membrane so that a portion of each pellet/granule extends beyond of the surface of the dry membrane. Suitable materials include a polymer (for example, polyethylene (including HDPE), polypropylene, polystyrene, polyvinylchloride, polyester, acrylic, rubber and combinations thereof), wood, metal and glass. The pellet/granule can also be formed from a hot-melt adhesive, such as those based on ethylene vinyl acetate copolymers, ethylene acrylate copolymers, polyester, polyethylene and polypropylene.
    The pellets/granules can be deposited in any suitable way in order to allow the pellets/granules to incorporate into the membrane. Pellets/granules can be applied at any desirable stage to the membrane. For example, the membrane can be fully wetted, partially dried or fully dried, as long as the membrane retains an adequate amount of adhesion to allow the pellets/granules to incorporate and be maintained. In a preferred embodiment, the pellets/granules are deposited in a grid-like or matrix-like pattern along the entire length of the integrated panel. The frequency of deposition of the pellets/granules is not particularly limited, as long as the anti-blocking property is maintained (eg, a spacing every 1 inch (2.54 cm), every two inches (5.08 cm), every three inches (7.62 cm), etc.). In a preferred embodiment, the placement of the pellets/granules does not interfere with the self-sealing effect provided by the membrane in relation to fasteners used during installation of the integrated panel.
    [0063] Additional modalities provide a method for fabricating an outer cladding panel with an integrated air/water barrier membrane. The method includes steps to prepare a cementitious slurry and fabricate a cementitious panel by sandwiching the slurry between two cover sheets. After the cement board is hardened, it is coated with an air/water barrier membrane. In some embodiments, a cementitious panel is manufactured by sandwiching a cementitious slurry comprising gypsum between two fiberglass mats. After the cementitious panel is hardened, it is spray coated, roll coated or dip coated with an air/water barrier membrane that is formulated as provided in Table 1. There are many advantages to a method described above. When performed under controlled conditions, including constantly monitored and maintained temperature, the method produces an outer cladding panel with an air/water barrier membrane with the consistent thickness, uniformity and even adhesive bonding of the membrane to the cementitious panel.
    [0064] An outer cladding panel with an air/water barrier membrane as described above has been found to have excellent membrane-to-panel adhesive strength and perform very well in adhesive strength tests, including the standardized ASTM C297 test. Table 2 below shows ASTM C297 bonding test results for an outer cladding panel with an air/water barrier membrane as described above and prepared by four different spray coating methods from A to D (Method A - coating by spraying outside the middle of the panel; Method B - spray coating from the coded edge; Method C - spray coating outside 4 feet across the longitudinal section; and Method D - hand sprayed with a hand pump).

    [0065] An outer cladding panel with an air/water barrier membrane as described above has been found to provide excellent membrane-to-panel adhesive strength and meet a minimum of 15 psi Z-directional tensile adhesive strength in the ASTM C297 binding test. As shown in Table 2 above, the average failure point for all panels is above 20 psi. Additionally, it was also found that the point of failure for all panels in Table 2 is within the panel itself, i.e. between the glass mat facer and the gypsum core.
    [0066] It has also been found that an exterior cladding panel formulated with an air/water barrier membrane formulated in accordance with Table 1 performs better than panels formulated with commercially available coatings such as EXOAIRTM 230, ICETM coating, TREMGARDTM HB (all from Tremco) in various tests including adhesion, UV stability, air permeability, ease of spray application viscosity, surface adhesion and blockage, and drying defects. Some comparative data are provided in Table 3 below.


    [0067] It has also been found that conditioning an outer cladding panel with an air/water barrier membrane in an oven prevents problems with panel blockage. Such conditioned panels have acquired an anti-blocking property and can be stored without the need for mesh or other insulating material.
    [0068] Additionally, it has been found that the best results are achieved when the panel is conditioned in an oven with two different temperature zones. In some embodiments, it is preferred that the panel is first conditioned in a first temperature zone with a lower temperature and then moved to a second temperature zone where the second temperature is higher than the first temperature in the first temperature zone. In some embodiments, the first temperature zone can be adjusted between 37.8 °C to 60 °C (100 °F to 140 °F) and the second temperature zone can be adjusted between 71 °C to 87.8 °C .(160°F to 190°F). This conditioning method to obtain an outer cladding panel with an integrated air/water barrier membrane with an anti-blocking property can be used for a panel with any integrated air/water barrier membrane described in this disclosure. In some embodiments, the etching method is used on an exterior cladding panel with an integrated air/water barrier membrane formulated with a polymer binder and calcium carbonate as provided in Table 1. As shown in Fig. 2A, a Integrated air/water barrier membrane formulated with a polymer binder and calcium carbonate as provided in Table 1 was subjected to conditioning in a higher temperature zone only. This panel has developed bubbles. Unlike the panel in Fig. 2a, a second integrated air/water barrier membrane formulated with a polymer binder and calcium carbonate, as provided in Table 1, was subjected to conditioning by a two-zone method. As shown in Fig. 2B, this second panel did not develop bubbles and had excellent anti-blocking property, without the need for a mesh or any other additional treatment.
    [0069] Any of the integrated panels described in this document may be part of a system that includes an integrated panel that is attached to one or more wall studs or ceiling beams by means of a fastener (eg, a screw, a nail ) with the integrated air/water barrier membrane as an outer coating material. Two adjacent panels are joined together by the seams using a suitable joint tape and joint compound. If desired, an additional intermittent layer can be added as an additional air and water barrier. A cladding material (eg siding, tile, stone) is additionally adhered to the outer cladding surface of the integrated panel. The entire system is designed to prevent air and water penetration through the panel into the structure.
    [0070] All references cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
    [0071] The use of the terms "a" and "the" and similar referents in the context of the description of the invention (especially in the context of the claims below) shall be interpreted to encompass both the singular as the plural, unless otherwise indicated in this document or in case of clear contradiction by the context. The terms "comprising", "having", "including" and "containing" shall be interpreted as open terms (ie, meaning "including, but not limited to") unless otherwise indicated. Recitation of the ranges of values in this document are only intended to serve as an abbreviated method of referring individually to each separate value that falls within the range, unless otherwise indicated in this document, and each separate value is incorporated into the descriptive report as if it were individually recited in this document. All methods described in this document may be carried out in any suitable order, unless otherwise stated in this document, or in case of clear contradiction by context. The use of any and all examples, or exemplary language (eg, "as") provided herein is only intended to further illuminate the invention and does not represent a limitation on the scope of the invention, unless otherwise claimed . No language in the descriptive report should be interpreted as indicating any element not claimed as essential to the practice of the invention. EXAMPLE 1 Fabrication of an exterior cladding panel with integrated air/water barrier membrane
    [0072] A cementitious panel was prepared with a cementitious core comprising gypsum that was sandwiched between two fiberglass mats. The cementitious panel was allowed to harden.
    [0073] An air/water barrier membrane was formulated with a polymeric binder, calcium carbonate and an antifungal agent as shown in Table 1. The cementitious panel was spray coated with the air/water barrier membrane. A second coated control panel was prepared in parallel.
    [0074] The first coated panel was conditioned in an oven to a first temperature zone at a temperature in the range of 37.8-60 °C (100140 °F) and was then moved to a second temperature zone and further conditioned in a temperature in the range of 71-87.8 °C (160 to 190 °F).
    [0075] The second coated control panel was conditioned in the same oven, but only in the second temperature zone at a temperature in the range of 71-87.8 °C (160 to 190 °F).
    [0076] While the first coated panel was fully conditioned, had no bubbles and had acquired an anti-blocking property, as shown in Fig. 2B, the second control panel was covered with coating bubbles which was removed and the panel was removed. control was not conditioned correctly as shown in Fig. 2A.
    权利要求:
    Claims (10)
    [0001]
    1. Cementitious panel CHARACTERIZED by the fact that it has at least one surface facing outwards and comprises a cementitious core, at least one cover sheet and an integrated air and water barrier membrane, wherein the cover sheet is sandwiched between the cementitious core and the integrated air and water barrier membrane, wherein the cover sheet comprises a fibrous mat comprising fibers, the fibers are coated or uncoated fibers and where the cover sheet is sandwiched between the cementitious core and the integrated air and water barrier membrane, wherein the integrated air and water barrier membrane is permeable to water vapor, wherein the integrated air and water barrier membrane is applied only to the outwardly facing surface of the cementitious panel ; and wherein the integrated air and water barrier membrane comprises from 30 to 70% by weight of a polymeric binder comprising a polyacrylate, polyurethane, silicone emulsion, polystyrene, styrene acrylic copolymer and combinations thereof; from 20 to 50% by weight of calcium carbonate; from 0.1 to 5% by weight of a wetting and leveling agent; and from 0.1 to 5% by weight of a crosslinker.
    [0002]
    2. Cementitious panel according to claim 1, CHARACTERIZED by the fact that the cementitious core comprises a cementitious material selected from the group consisting of a calcium sulfate material, Portland cement and a mixture thereof.
    [0003]
    3. Cement panel, according to claim 1, CHARACTERIZED by the fact that the fibrous mat is woven or non-woven.
    [0004]
    4. Cement panel according to claim 3, CHARACTERIZED by the fact that the fibrous mat comprises polymer fibers, mineral fibers or a combination thereof.
    [0005]
    5. Cement panel according to claim 1, CHARACTERIZED by the fact that the integrated air and water barrier membrane has a dry thickness in the range of 0.254 to 2.286 mm (10 to 90 mils).
    [0006]
    6. Cementitious panel, according to claim 1, CHARACTERIZED by the fact that at least one of the following: the cementitious core, the cover sheet and the integrated air and water membrane comprises an antimicrobial agent selected from the group consisting of 2-(4-thiazolyl)benzimidazole, silver zeolite, zinc oxide and zinc pyrithione.
    [0007]
    7. Method for manufacturing an outer cladding panel with an integrated air and water barrier membrane, CHARACTERIZED in that it comprises the following steps: preparing a slurry comprising a cementitious material; sandwich the slurry between two cover sheets; allowing the slurry to harden and thereby form a cementitious panel; coating the cementitious panel on at least one surface with an integrated air and water barrier membrane, wherein the integrated air and water barrier membrane comprises from 30 to 70% by weight of a polymeric binder comprising a polyacrylate, polyurethane, emulsion silicone, polystyrene, styrene acrylic copolymer or any combination thereof; from 20 to 50% by weight of calcium carbonate; from 0.1 to 5% by weight of a wetting and leveling agent; and from 0.1 to 5% by weight of a spray coating, roll coating or spray coating crosslinker; and conditioning the coated cementitious panel in an oven, wherein the panel is exposed to at least two different temperature zones, a first temperature zone and a second temperature zone; and wherein a temperature in the first temperature zone is lower than a temperature in the second temperature zone.
    [0008]
    8. Method according to claim 7, CHARACTERIZED by the fact that the temperature in the first temperature zone is in the range of 37.8 °C to 60 °C (100 °F to 140 °F) and where the temperature in the second temperature zone it is in the range of about 71°C to 87.8°C.(160°F to 190°F).
    [0009]
    9. Cementitious panel, according to claim 1, CHARACTERIZED by the fact that the wetting and leveling agent comprises at least one of the following: sulfosuccinate, polyether-modified siloxane, urea-modified polyurethane, or a urea-modified ammonium salt of an acrylate copolymer.
    [0010]
    10. Cementitious panel, according to claim 1, CHARACTERIZED by the fact that the crosslinker comprises at least one of the following: zinc oxide, zinc metal ions, anionic hydroxylated zirconium polymers containing ammonium stabilized zirconium carbonate, or epoxy functional silane.
    类似技术:
    公开号 | 公开日 | 专利标题
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    同族专利:
    公开号 | 公开日
    AU2014228187A1|2015-10-15|
    US20200147930A1|2020-05-14|
    TWI622694B|2018-05-01|
    US11267227B2|2022-03-08|
    US20200171797A1|2020-06-04|
    CA2904667C|2021-03-23|
    US20200331236A1|2020-10-22|
    TW201441457A|2014-11-01|
    JP6498178B2|2019-04-10|
    US10906271B2|2021-02-02|
    PE20152012A1|2016-01-09|
    CA2904667A1|2014-09-18|
    NZ712569A|2020-04-24|
    EP2969543B1|2020-12-02|
    ES2846734T3|2021-07-29|
    CL2015002418A1|2016-08-12|
    KR20160011616A|2016-02-01|
    JP2016520443A|2016-07-14|
    MX2015011307A|2016-03-04|
    CN105209251A|2015-12-30|
    WO2014143780A1|2014-09-18|
    EP2969543A1|2016-01-20|
    US20140272404A1|2014-09-18|
    CN105209251B|2018-09-07|
    AR095378A1|2015-10-14|
    RU2663040C2|2018-08-01|
    RU2015141373A|2017-04-17|
    US10562271B2|2020-02-18|
    UA117363C2|2018-07-25|
    AU2014228187B2|2017-10-19|
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    法律状态:
    2018-02-27| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2020-02-04| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2021-03-02| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-05-18| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 14/03/2014, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US201361792545P| true| 2013-03-15|2013-03-15|
    US61/792,545|2013-03-15|
    US14/198,093|2014-03-05|
    US14/198,093|US10562271B2|2013-03-15|2014-03-05|Exterior sheathing panel with integrated air/water barrier membrane|
    PCT/US2014/027887|WO2014143780A1|2013-03-15|2014-03-14|Exterior sheathing panel with integrated air/water barrier membrane|
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