Building product including a metal carbonate and a process of forming the same

Patent metadata

Field	Value
Publication number	US-9840845-B2
Application number	US-201314023141-A
Country	US
Kind code	B2
Filing date	Sep 10, 2013
Priority date	Sep 14, 2012
Publication date	Dec 12, 2017
Grant date	Dec 12, 2017

Abstract

A process of forming a building product can include providing a first layer having a first material, and providing a second layer having a second material that different from the first material, wherein the second layer has pores. The process can further include infiltrating a fluid into the pores of the second layer while the first layer is present and adjacent to the second layer, wherein the fluid includes a carbonate. The process can still further include reacting the carbonate with a metal compound within the second layer to form a metal carbonate within the second layer. In another aspect, a building product can include a first layer having a first material, and a second layer having a second material and a third material that includes a metal carbonate. The first material can be different from the second material, and the second and third materials can include the same metal element.

First claim

What is claimed is:

1. A building product comprising:
a first layer having a first material;
a second layer having a second material and a third material; and
an outer surface, wherein:
the first material is different from the second material;
an inner surface of the first layer contacts the second material and the third material, and an outer surface of the first layer defines a majority of the outer surface of the building product;
the second material comprises a metal element;
the third material forms a portion of the outer surface and comprises a metal carbonate including the metal element.

2. The building product of claim 1 , wherein the first material has a smaller average diameter as compared to the second material.

3. The building product of claim 1 , wherein the second material has a D10 average diameter of at least approximately 0.001 microns.

4. The building product of claim 1 , wherein the first material has a D10 average diameter of at least approximately 0.001 microns.

5. The building product of claim 1 , wherein the first layer has a smaller amount of open porosity as compared to the second layer.

6. The building product of claim 1 , wherein the first layer occupies a first volume, the second layer occupies a second volume, and a ratio of the second volume to the first volume is at least approximately 1.1:1.

7. A building product comprising:
an exterior layer comprising a first material;
an intermediate layer comprising a second material; and
an interior layer comprising a third material, wherein:
the intermediate layer is disposed between the exterior and interior layers;
the first material comprises a first metal element;
the second material comprises a carbonate including the first metal element;
the third material comprises a carbonate including a second metal element different than the first metal element; and
each of the first, second, and third materials define a portion of an outer surface of the building product.

8. The building product of claim 1 , further comprising an antimicrobial agent comprising a photocatalytic antimicrobial agent adjacent to a surface of the first layer that is opposite another surface of the first layer that lies closer to the second layer.

9. The building product of claim 1 , wherein the first layer further comprises a particular metal carbonate, wherein the first material and the particular metal carbonate comprise a same metal element.

10. The building product of claim 1 , wherein the second material and the third material form discrete sublayers within the second layer.

11. The building product of claim 1 , wherein the first material, the second material, or the first and second materials include a low density filler material or a void containing filler material.

12. The building product of claim 1 , wherein a solubility of the metal carbonate in water at 20° C. is less than about 0.05 grams per 100 grams of water.

13. The building product of claim 1 , wherein the building product comprises a roofing product.

14. The building product of claim 1 , wherein the building product comprises cladding for a building structure.

15. A process of forming the building product of claim 1 comprising:
providing a first layer having a first material;
providing a second layer having a second material that different from the first material,
wherein the second layer has pores;

infiltrating a fluid into the pores of the second layer while the first layer is present and adjacent to the second layer, wherein the fluid includes a carbonate; and
reacting the carbonate with a metal compound within the second layer to form a metal carbonate within the second layer,
wherein the building product has an exterior surface defined by a portion of the first layer and a portion of the second layer.

16. The process of claim 15 , wherein a solubility of the metal carbonate in water at 20° C. is less than about 0.05 grams per 100 grams of water.

17. The process of claim 15 , wherein providing the first layer and providing the second layer comprises:
partly filling a first portion of a mould with the first material; and
filling a second portion of the mould with the second material after partly filling the first portion.

18. The process of claim 15 , wherein providing the first layer comprises extruding the first layer onto the second layer before infiltrating the second layer.

19. The process of claim 15 , wherein the first layer occupies a first volume, the second layer occupies a second volume, and a ratio of the second volume to the first volume is at least approximately 1.1:1.

20. The process of claim 15 , wherein the fluid comprises a liquid.

21. The process of claim 15 , wherein the building product further comprises an antimicrobial agent comprising a photocatalytic antimicrobial agent adjacent to a surface of the first layer that is opposite another surface of the first layer that lies closer to the second layer.

22. The process of claim 15 , wherein the building product comprises a roofing product.

23. The process of claim 15 , wherein the building product comprises cladding for a building structure.

Assignees

• Kalkanoglu Husnu M
• Jacobs Gregory F
• Certain Teed Corp

Inventors

• Kalkanoglu Husnu M
• Jacobs Gregory F

Classifications

• E04D1/22 Primary

  of specified materials {not covered by any one of groups E04D1/14 - E04D1/205}, or of combinations of materials, {where at least one is} not covered by any one of groups E04D1/14 - E04D1/205 · CPC title

• E04F13/18

  of organic plastics with or without reinforcements or filling materials (of plastic-bound fibres or chips E04F13/16 ){or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles (E04F13/0864 takes precedence)} · CPC title

• Y10T428/24942

  including components having same physical characteristic in differing degree · CPC title

• Y10T428/249971

  Preformed hollow element-containing · CPC title

• E04F13/0866

  composed of several layers, e.g. sandwich panels or layered panels (layered products as such in general B32B; producing decorative panels or veneers B44C5/04; E04F13/0864, E04F13/0875 take precedence) · CPC title