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Composite productRelated Patent Categories: Stock Material Or Miscellaneous Articles, Composite (nonstructural Laminate)Composite product description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070077436, Composite product. Brief Patent Description - Full Patent Description - Patent Application Claims
[0001] Pursuant to 35 U.S.C. .sctn.120, this continuation application claims priority from, and hereby incorporates by reference for all purposes, copending U.S. patent application Ser. No. 11/128,778 entitled Composite Product, naming Basil Naji, John Sydney Cottier, and Robert Lyons as inventors, filed May 13, 2005, which pursuant to 35 U.S.C. .sctn.120 claims the benefit of U.S. patent application Ser. No. 10/090,406 (Issued U.S. Pat. No. 6,893,751, issued May 17, 2005) entitled Composite Product, naming Basil Naji, John Sydney Cottier, and Robert Lyons as inventors, filed Mar. 4, 2002, which claims priority from the following Australian provisional patent applications, the full contents of which are hereby incorporated by reference for all purposes: TABLE-US-00001 App. No. Title Date Filed PR3474 A Composite Product 2 Mar. 2001 PR3475 Spattering Apparatus 2 Mar. 2001 PR3476 Additive for a Dewaterable 2 Mar. 2001 Slurry PR3477 A Method and Apparatus for 2 Mar. 2001 Forming a Laminated Sheet Material by Spattering PR3478 Coatings for Building 2 Mar. 2001 Products BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to composites and particularly, but not limited to, fibre reinforced building composites. [0004] 2. Description of the Related Art [0005] Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field. [0006] Fibre reinforced cement (FRC) is an extremely popular building product. [0007] The applicant along with other various parties have developed a variety of techniques for producing fibre reinforced cement building products and tailoring those FRC products to the particular environment of use. [0008] There are still, however, certain limitations with regard to FRC products. They have limited acoustic, thermal and fire retardant properties. They can exhibit limited workability and generally lie in the medium density range (around 1300 kg/m.sup.3) or higher (compressed densities of around 1700 kg/m.sup.3). [0009] Generally, the properties of fibre cement are altered by addition of other materials eg different fibres, fillers etc or altered with different production techniques. Such alterations to the FRC formulation, however, can be expensive to develop in order to ensure no detrimental side effects arise from such new formulations. Alterations in production methods or equipment are also expensive and time consuming to develop. Such techniques also do not provide for true "tailoring" of the FRC product. It is, of course, inappropriate to shut down an entire production line, for example, to produce a small batch of FRC product tailored to a specific use. [0010] It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative. SUMMARY OF THE INVENTION [0011] In a broad aspect, the present invention provides a composite product comprising a substrate layer and one or more functional layers applied thereto, each functional layer including a mixture of hydraulic binder, dewatering agent wherein the quantity of dewatering agent is sufficient to permit de-watering of each functional layer through the substrate layer and any additional functional layer. [0012] In a second aspect, the present invention provides a method of manufacturing a composite product comprising: [0013] (i) providing a substrate layer, [0014] (ii) providing a slurry formulation including an hydraulic binder and dewatering agent, [0015] (iii) applying said slurry to said substrate layer to form a functional layer, [0016] (iv) dewatering the functional layer, and [0017] (v) optionally repeating steps (ii) through (iv), wherein the quantity of dewatering agent is sufficient to maintain porosity and thereby permit de-watering of each functional layer through the substrate layer and any additional functional layer. [0018] Preferably, the substrate layer is a fibre reinforced base material such as fibre reinforced cement. This substrate layer provides a structural base on which additional functional layers may be added. [0019] The functional layers may be added to both sides of the substrate layer but most preferably are added to one side which generally expose one side of the building board during production. Such a technique allows the aforementioned method to be applied to current FRC production techniques such as Hatschek. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0020] The present applicants have developed a process for manufacture of a composite article to virtually any desired specification or use. To explain, the present inventive composite and method starts with a simple water permeable substrate layer such as conventional fibre reinforced building board. To this base layer are added one or more functional layers, each functional layer being specifically tailored to provide the desired functionality. For example, if it is desired to provide an insulating layer, the slurry formulation from which the functional layer is formed can include insulating materials such as rubber crumbs, vermiculite, perlite, gypsum, etc. [0021] Similarly, water permeability may be decreased by including water resistant polymers eg silanes, siloxane blends etc or pozzalanic materials such as silica fume, metakaoline, ultrafine fly ash etc. [0022] Density modification of the functional layer can be accomplished by addition of suitable light weight materials such as cenospheres (ceramic hollow spheres), expanded polystyrene, vermiculite, perlite etc. [0023] The inventive process enables various functional layers to be integrated into a single composite by appropriate slurry modification. [0024] In a preferred embodiment, each functional layer has a reinforcing layer positioned therebetween. The reinforcing layer may comprise fibre mesh or netting, and serves to improve the strength and durability of the composite product. [0025] In some instances, the reinforcing layer may comprise a thin fibre reinforced cementitious layer similar for instance to the base material. This provides for more efficient utilisation of such fibre reinforced layers, similar to sandwich composite technology. It will be appreciated by a person skilled in the art, that there are areas of a composite which require less fibre reinforcement ie the core. Such a core area can be formed as the aforementioned functional layer with low fibre reinforcement. Areas which require high fibre reinforcement due to high tensile strength ie surface or skin areas, can be covered by a fibre reinforced cementitious layer. The thus formed fibre reinforced layers act as sandwich skins with a de-watered slurry functional layer acting as a sandwich core. [0026] As a result, the described composite provides significant advantages over monolithic fibre reinforced composites. Firstly, by the aforementioned composite action, fibres can be positioned in areas where they are most required. This will, of course, lead to a reduction in the fibre reinforced volume of the product. Continue reading about Composite product... Full patent description for Composite product Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Composite product patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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