Fiber cement cladding system

Patent metadata

Field	Value
Publication number	US-11193281-B2
Application number	US-202016934638-A
Country	US
Kind code	B2
Filing date	Jul 21, 2020
Priority date	Mar 22, 2018
Publication date	Dec 7, 2021
Grant date	Dec 7, 2021

Abstract

Disclosed herein is a fiber cement cladding system such as fiber cement shingles or shakes which can have the appearance of authentic wood. Each individual fiber cement shingle or shake comprises a textured surface having a depth of relief and a coating system disposed on the textured surface. The coating system may include a sealing agent, a basecoat, and a topcoat. In some embodiments, the basecoat is disposed on at least a portion of the sealing agent and the topcoat is disposed on at least a portion of the basecoat. In some embodiments, the basecoat comprises a DFT of 1 to 3 mils and the topcoat comprises a DFT of 0.05 to 2 mils. In some embodiments, the depth of relief of the textured surface of the fiber cement shingle is about 0.03″ to 0.085″.

First claim

What is claimed is:

1. A cladding system configured to be installed in courses on an exterior of a building structure, the cladding system comprising:
a plurality of fiber cement cladding elements comprising:
a first fiber cement cladding element comprising a first fiber cement substrate, said first fiber cement substrate having a textured surface comprising a wood grain pattern, wherein the textured surface has a depth of relief ranging from 0.03 inch (0.762 mm) to 0.085 inch (2.159 mm); and
a second fiber cement cladding element comprising a second fiber cement substrate, said second fiber cement substrate having a textured surface comprising a wood grain pattern, wherein the textured surface has a depth of relief ranging from 0.03 inch (0.762 mm) to 0.085 inch (2.159 mm);

a coating system disposed on the textured surface of each of the fiber cement substrates of the fiber cement cladding elements, the coating system comprising:
a sealing agent, the sealing agent comprising a two-part waterborne epoxy sealer comprising a sealing agent Dry Film Thickness (DFT) between 0.45 and 0.55 mils;
a basecoat disposed on a portion of the sealing agent, the basecoat comprising a first Dry Film Thickness (DFT) between 1 and 3 mils; and
a topcoat disposed on a portion of the basecoat, the topcoat comprising a second Dry Film Thickness (DFT) between 0.5 and 1.5 mils, wherein the second DFT is smaller than the first DFT, and wherein the topcoat enhances the basecoat and textured surface; and

wherein the depth of relief on each of the fiber cement substrates in combination with the coating system cause varied color values within each of the fiber cement cladding elements and between the fiber cement cladding elements;
wherein the first and second fiber cement cladding elements comprise different CIELAB color values that differ by a difference dE, and wherein the difference dE is between 3 and 10.

2. The cladding system of claim 1 , wherein the first DFT is between 1.6 and 1.9 mils and the second DFT is between 0.7 and 0.8 mils.

3. The cladding system of claim 1 , wherein the sealing agent has a solids content between 15 and 25% by weight.

4. The cladding system of claim 1 , wherein the sealing agent further comprises one or more pigments.

5. The cladding system of claim 1 , wherein the basecoat has a solids content between 55 and 60% by weight.

6. The cladding system of claim 1 , wherein the topcoat has a solids content between 32 and 35% by weight.

7. The cladding system of claim 1 , wherein:
the basecoat comprises a first CIELAB color value comprising an L value between 55.59 and 78.85, an a value between 0.68 and 15.52 and a b value between 5.19 and 36.32; and
the topcoat comprises a second CIELAB color value comprising an L value between 61.15 and 65.75, an a value between −1.3 and 6.91, and a b value between −0.45 and 10.69.

8. The cladding system of claim 1 , wherein:
the basecoat comprises a first CIELAB color value comprising an L value of approximately 61.27, an a value of approximately 0.68 and a b value of approximately 5.19; and
the topcoat comprises a second CIELAB color value comprising an L value of approximately 62.1, an a value of approximately −1.3, and a b value of approximately −0.45.

9. The cladding system of claim 1 , wherein:
the basecoat comprises a first CIELAB color value comprising an L value of approximately 55.59, an a value of approximately 14.85, and a b value of approximately 20.76; and
the topcoat comprises a second CIELAB color value comprising an L value of approximately 61.15, an a value of approximately 6.03, and a b value of approximately 7.13.

10. The cladding system of claim 1 , wherein the basecoat has a weight percent non-volatile material (NVM) of between 50 and 60 percent and the topcoat has a weight percent non-volatile material (NVM) of between 30 and 40 percent.

11. The cladding system of claim 1 , wherein the topcoat further comprises a UV absorber and a Hindered Amine Light Stabilizer (HALS) additive.

12. A cladding element configured to replicate an appearance of a natural wood cladding element, the cladding element comprising a fiber cement substrate and further comprising:
a textured surface, the textured surface comprising a wood grain pattern having a depth of relief ranging from 0.03 inch to 0.085 inch; and
a coating system disposed on the textured surface, the coating system comprising:
a sealing agent, the sealing agent comprising a two-part waterborne epoxy sealer;
a basecoat disposed on a portion of the sealing agent, the basecoat comprising:
a Dry Film Thickness (DFT) between 1 and 3 mils; and
a first CIELAB color value comprising a first L value, a first a value, and a first b value; and

a topcoat disposed on a portion of the basecoat, the topcoat comprising:
a Dry Film Thickness (DFT) between 0.5 and 1.5 mils, wherein the DFT of the topcoat is smaller than the DFT of the basecoat; and
a second CIELAB color value comprising a second L value, a second a value, and a second b value;

wherein the first CIELAB color value and the second CIELAB color value differ by a difference dE, and wherein the first L value is greater than the second L value.

13. The cladding element of claim 12 , wherein the wood grain pattern comprises circular saw marks.

14. The cladding element of claim 13 , wherein the circular saw marks have a diameter between 42 inch (106.68 cm) and 46 inch (116.84 cm).

15. The cladding element of claim 12 , wherein the DFT of the basecoat is between 1.6 and 1.9 mils and the DFT of the topcoat is between 0.7 and 0.8 mils.

16. The cladding element of claim 12 , wherein the difference dE between the first CIELAB color value and the second CIELAB color value is between 3 and 7, and wherein:
the first L value is approximately 61.27 and the second L value is approximately 62.1;
the first a value is approximately 0.68 and the second a value is approximately −1.3;
the first b value is approximately 5.19 and the second b value is approximately −0.45.

17. The cladding element of claim 12 , wherein the basecoat has a weight percent non-volatile material (NVM) of between 50 and 60 percent and the topcoat has a weight percent non-volatile material (NVM) of between 30 and 40 percent.

18. A building article having an appearance of wood, the building article comprising a fiber cement substrate having a textured surface and a coating system disposed on the textured surface, wherein the textured surface comprises a depth of relief, the depth of relief ranging from 0.01 inch (0.254 mm) to 0.3 inch (7.62 mm), and wherein the coating system comprises:
a basecoat, the basecoat comprising:
a first Dry Film Thickness (DFT) between 1 and 3 mils; and
a first CIELAB color value comprising a first L value, a first a value, and a first b value; and

a topcoat, the topcoat comprising:
a second Dry Film Thickness (DFT) between 0.5 and 1.5 mils, wherein the second DFT is smaller than the first DFT; and
a second CIELAB color value comprising a second L value, a second a value, and a second b value;

wherein the first CIELAB color value and the second CIELAB color value differ by a difference dE, and wherein the first L value is greater than the second L value.

19. The building article of claim 18 , wherein the textured surface comprises a wood grain pattern.

20. The building article of claim 18 , wherein the coating system further comprises a sealing agent, the sealing agent comprising a two-part waterborne epoxy sealer.

21. T

Assignees

• Hardie James Technology Ltd

Inventors

• Joecken John
• Tinen William J
• Kies Jared E

Classifications

• B05D2203/30

  Other inorganic substrates, e.g. ceramics, silicon · CPC title

• E04F13/0871 Primary

  having an ornamental or specially shaped visible surface (E04F13/0867 takes precedence) · CPC title

• B05D3/104

  Pretreatment of other substrates · CPC title

• B44C5/04

  Ornamental plaques, e.g. decorative panels, decorative veneers · CPC title

• B05D7/586

  each layer being cured, at least partially, separately · CPC title