AU606699B2

AU606699B2 - Insulated plaster board

Info

Publication number: AU606699B2
Application number: AU18820/88A
Authority: AU
Inventors: Francisco Andres Cruz
Original assignee: Individual
Current assignee: Individual
Priority date: 1987-07-07
Filing date: 1988-07-07
Publication date: 1991-02-14
Anticipated expiration: 2008-07-07
Also published as: AU1882088A

Description

A

'p 606 9 9 F 'Ref: 29083 FORM COMMONWEALTH OF AUSTRALIA PATENTS ACT 1952 COMPLETE SPECIFICATION EThis document contains tile aril1'dmclnts matde ufldcr c'ection 49 and is Correct fr P1rinti ng.

1 fo Class Int. Class (OR I GINAL) FOR OFFICE USE: 0 0 Application Number: P12941 Lodged: 7 July 1987 Accepted: Published: Priori ty: Related Art: 00: 4 Name and Ad,',ess of Applicant: 00 00 0 0 Actual Invertor: 0 00 Francisco Andres Cruz 35 Booth Street Annandale New South Wales 2038

AUSTRALIA

Francisco Andcres Cruz Address for Service: Spruson Ferguson, Patent Attorneys, Level 33 St Martins Tower, 31 Market Street, Sydney, New South Wales, 2000, Australia Complete Specification for the invention entitled: Insulated Plaster Board The following statement is a full description of this best method of performing it known to me/us invention, Including the sCoooD:Y4 5815/2 07/0D7/88

II

1A INSULATION BOARD AND COMPOSITE SHEET Background of the Invention The present invention relates to an insulation board and composite sheet, and more particularly but not exclusively to a composite sheet for lining walls, providing ceilings, roofs, floors and the like in buildings.

Many varied products are used by the building industry to line internal walls and ceilings in buildings, houses and the like. Some of these include gypsum board, fibrous plaster and low density particle boards, as well as construction members sold under the designations Villaboard TM and Masonite TM. Other products which are used by the building industry include internal tiles, external roof tiles, shingles and the like.

0 .0 However, all the commonly used materials suffer at least one of the following drawbacks: brittleness, inability to withstand high 0 0 ,15 humidity, high weight/area ratio, susceptibility to warpage, and 0o ineffective insulator.

0 Q 0 Summary of the Invention 0 It is therefore the object of the present invention to overcome or substantially ameliorate the above-mention problems.

According to a first embodiment of this invention there is provided an article comprising an Insulating board having a plurality of i perforations therein arranged in an array, said board being formed from low ,i °density material and having an upper surface and a lower surface, at least one of said surfaces having surface deformations, said deformations including indentations at least laterally spaced from all of said preforations and at least one of said surfaces having a plurality of areas of reduced thickness.

According to a second embodiment of this Invention there is provided i a composite sheet comprising an insulating board having a plurality of perforations therein arranged In a array, said board being formed of low density material and having an upper surface and a lower surface, at least Sone of said surfaces having surface deformatlons, said deformations including indentations spaced from said preforations and a plurality of areas of reduced thickness, at least some of which are coincident with said i preforations; and a material of higher density than the density of the board applied to at least one of said upper surface and said lower surface and extending through said preforations and filling said deformations. L r i- -2- According to a third embodiment of this invention there is provided a process for producing the composite sheet of the second embodiment comprising providing an insulating board of low density material having perforations therein and surface deformations in at least one of its upper surface and its lower surface; and filling the perforations and the deformations with a material so as to cover at least one of said upper surface and said lower surface.

Brief Description of the Drawings Preferred forms of the present invention will now be described by way of example with reference to the accompanying drawings, wherein: Fig. I is a perspective view of a formed low density Insulation board constructed in accordance with the present invention.

Fig. 2 is a cross sectional view of a portion of a composite sheet f. ,9 incorporating the formed low density insulation board of Fig. i, the ,15 section having been taken through the insulating board of Fig. 1 along section line 2-2.

Fig. 3 is a perspective view of a formed low density insulation board constructed in accordance with the present invention, the board being a first variant of the board of Fig. I.

Fig. 4 is a cross sectional view of a portion of a composite sheet incorporating the formed low density insulation board of Fig. 3, the section having been taken through the insulating board of Fig. 3 along section line 4-4.

Fig. 5 is a perspective view of a formed low density insulation board constructed in accordance with the present invention, the board being a second variant of the board of Fig. 1.

Fig. 6 is a cross sectional view of a portion of a composite 1 KEH/25751

I

seet licorporatiig the forMied low denalty insati 5ard sC FIG. 5, the section having buen taken tgh the Ininlating board of FIG. 5 along section line 6-S, Detailed Desc-ription of the Prefecred Embodiments In FIG. 1 of the accomipanying drawinga thero is schenatically depicted a formed low density insulation board 10, proferably made of polysterene foamra. The board 10 is provided with a plurality of surface deformations including a plurality perforations 11 arranged in an array. The perforations 11 are preferably bored through the board 10, but could be formed using o any number of coventional techniques. In the preferred erbodi- I 0 0 0 o0 0o o 00 Bent shown in FIG. 1, the surface deformations further include a 0o 0 plurality of semispherical indentations 13 on the upper and 0 o lower surfaces of the board 10 between the perforations 11 and a plurality of parallel slots 14 coincident with the rows and/or S0 0.

o 0 columns of the array of perforations 11. In the lower surface 0°0° of the board 10, a second plurality of parallel slots 14 is 00 provided, these slots also being coincident with the rows and/or columns of the array of perforations 11. The slots 14 in the upper surface of the board 10 run perpendicular to those in the o %bottom surface. The slots 14 are semicircular in cross section.

The board 10 can be used in combination with a material of higher density, such as for example as illustrated in FIG. 2, calcined gypsum 20 plaster of Paris), with paper sheets 21 or the like applied to the upper and lower surfaces to provide a composite sheet 15 for lining walls and/or ceilings. Either one or both of the paper sheets 21 could be replaced, if desired, with respective sheets of plastic or inmetal fixed to the respective upper and lower surfaces of the board 10, were it desired to use the sheet as a tile or the like. It is to be understood that the calcined gypsum 20 could extend along the edges of the board 10, in effect encapsulating the bourd and -3proidig ameprotacvlon for the board.

To mak th uhe fl~ z3nqt calctnced gypsiv plcaster 20 is appi Led to both the top and bot om snrfae*~ of, the board 10. The plaster 20 the porforatioiss It,* the indentations 13 and the slots 14. 41 relatively thin layer of p Ia s Zar 20 renaine adjacent to both the too and bottora surfaces of the board its motioned above, the pla.ter 20 may e,:tend along the ed-es og the board 10, protecting the board and] adding additional strength. When dry the board 10 reinforces the plaster 20 and vice 0 versa. The plaster 20 which exztends through the perforations IL 0 0 provides, in particular, considerable strength against comprecsion forces; the plaster 20 in the slots 14 and in the indentations 13 provide strength and resistance against banding of the sheet Ila. The paper sheets 21 or the plastic or metal sheets which nay be used Ino some applications add further strength to the sheet :::0Further, reinforcing fibres 22, fibre glass, hemp, coconut fibres, and the like) can be mixed with unseat plaster to further improve the qualities of the board In FIG. 3 of the accompanying drawings there is schematical- 4.ly depicted a formed low density insulation board 30, preferably made of polysterene foam or the like. The board 30 is provided with a plurality of surface deformations, including a plurality of perforations 34 arranged in a pattern. The perforations 34 are preferably bored through the board 30, but could be formed using any number of conventional techniques. In the preferred variant shown in FIG. 3, the sur face deformations further include a plurality of saerispherical formations 31 arranged In respective arrays on the top and bottom of the board 30 between the perforations 34, defining Interconnected flat areas at the bases of the formations 31. Thea fla t areas are coincident with the perforations 34. Rlespective apertures 33 extend froma the apaxota of reaptctive .4Luiphea icu' foc-i".1tona 31 on the upper -4 nur ace al the hbe r 3nl t Q rppa :1 vo ca nsd Igog a pogs OF? oensp~erci. ~i&~ion 3~05 hO 10ko G&c urfaCO Of Mhe board.

The p~rpo-se of the aperteres 33, which riay be of lesver islnator than the perforations 34, is to allow air to esae from~ beneath the board 30 during formation of the composice shcet ohvn In F1 G especti ve samispherical. depressions 32 are pro vided at enter and fill the apertures.

00 02The board 30 can be use in combination with a materilo jhigher density, such as Eur examnple as illustrated in rIG. 4, 0 ,calcined gypsum 35 plaster of Paris), with respective paper sheets 36 and 37 o r the like applied to the upper and lowier surfaces or provide a composite sheet for lining walls 0000 and/ or ceilings. Either one or both of the paper sheets, 36 cand 00000 37 could be replaced, if desired, ti th respective sheets of plastic or natal fixed the respective top or bottos of the *composite sheet, were it desired to use the sheet as a tile or the like. It is to be tinderstood that the calcined gyps-uo 0could extend along the edges of the board 30 encapsulating cad providing some protection Ear the board.

To m a Ie the comoite sheet illuitratad In MI. 4t, unoet calcined gypsum~ plaster 35 is applied to both the top and bottom surfaces of the board 30. The placter 35 filln the perforationo 34, the apertures 33, the depressions 32 and the spacas between the formations 31. A relatively thin layer of plaster remains adjacent to both the top1 and bottom surfaces of the board 30. As mentioned above, the plaster 35 may extend alon.th(, edges of the board 30, protecting tne board and adding additional strength. 11h an dry the board 30 reinforces the plaster 35 and vice versa. The p aster 35 in th flat areas between the formationn 31 provide strenath a n resistance~

L

OIl~ 0 0 0 000000 0 0 0 00 0 0 0 0 DOd against beading Of the comoite shoot.

Fuorther, reinforcing fibres, fibre glass, hemp, coconut fibres, and the like can be nined with unnet plaster as InI tile sheet Illustrated in FIG. 2, to further imurove the qualities of the componite board of FIG. 4.

In FIG, 5 of the accompanying drawings there Is scheatically depicted a formed low density insulation board 40, preferably made of pol.ysterene foam. The board 40 is provided with a plurality of surface deformations includina a plurality of perforations 43 arranged in an array. The perforations 43 are preferably bored through the board 40, but could be formed using any nunber of conventional techniques. In the preferred variant shown in FIG. 5 the surface deformations further include a plurality of spaced-apart parallel clots 41, of triangular cross section, in the upper surface of the board 40 between rows of the perforations 43 and a second plurality of spaced-apart parallel slots 42 between columns of the perforations 43, The slots 42 ran perpendicular to the slots 41 and, like the slots 41, are of triangular cross section. In the lower surface of the board 40, a third plurality of spaced-apart parallel slots 44 and a fourth plurality of spaced-apart slots 45 are provided, these pluralities of slots being respectively coincident with the rows and columns of the array of perforations 43. The slots 44 and 45 are of triangular cross section.

The board 40 can be used in combination with a material of higher density, such as for example as illustrated in FIG. 6, calcined gypsum 46 plaster of Paris), with respective poper shoets 47 and 48 or the like applied to the upper and lower surfaces to provide a composite sheet for lining walls and/or ceilings. Either one or both of the paper sheets; 47 and 48 could be replnced, if desired, with respective sheets of plautC or wttl W ~ed to tho tippar and lower sttrfttcau of the compautte shet, qero it desired to use tno tacuet as a tilu, ohingle or the Meh. It Is to to uderstoc thlat t:he CBclapd Mys"~ 4Ci coutd "Ca:tnd ag thO edges of the boar" 401, prvtding some protection for the board and encapsulacing It.

To. make the shee illustrated in P19 6. unset calci!ned gypsum plaster 46 Is applied to both the upper and lower orfacas oQ the board 40. The plaster 46 fills thG- peorforations e43, the clots 41, 42, 44 and 45. A relatively thin 1ayer of plaster 46 remains adjacent to both the upper and lower surfaces of the board 40. As mcutionejd above, the plastev 46 any nd along the edges of the board 40, protecting the Hoard and adding 0 .additional strength. The plaster 46 which entends through the 0 perforations 43 provides, in particular, con~siderable strength against conpresion forces; the plaster 46 In the slots 41 ,42.44 and 45 provide strength and resistance to bending and twisting forces. The paper sheets 47 and 40 or the plastic or, aetal 0 o10: sheets which may be used In same applications add further 0 strength to the composite sheet of VIG. 6.

04As in the cases of FIGS. 2 and 4, reinforcinG fibres, (e.g.

fibre glass, hemp, coconut fibres, and like) caa be Dined with the unset plaster 46 to further improve the qualities of the o board in the same manner as the fibres 22 rainforce the composite aheet 15 (FIG. 2).

The composite sheet 15 of FIG. 2, as wa:ll am thowe showe In FIGS. 4 and 6, is a sheet of lighter constrtiction than present commonly used materials, and cn be of equal, or greater strangth. It is durable, and less likely to sag or warp in use. The polysterene insulation board 10 of FIG. as aell as those illustrated in FIGS. 3 and 5, provides the composite sheets, IQ euch case, with a relatively low coefticient of hat transfer (ime, the plaster board has good insulative properties) aad a high resistance to moisture absorption.

A componite aheet has been described wlierein a polyntyvrene Insulation board is Incorporat.4 In .0ater mssterlal. howvors 000 0 00 0 0 0 44 0 00 then polyLyvyint- inaulao n ivrtc"I ae ao10use)d inac~~a With a widfh Val~ietv 01 a t"e m 1: va ~i I s uch ao a WM c at o Ot6O1 a L p r 0d uce t I 5r G' I It t o a of c i t a Lit) For ex a M 0 hy7d ra u iCca 2.n t a nucrh1 a a 11rL Putia nd cement, Cemnlto psesinn q u a!I tea such no rapid hluiG, low huat tasfer, sulphate ruiting Ci.a. quali~ties due to additiveo);- cement m uI:oo ,t uch1 a.3 o0.1ta r-0 n t, t.ire camonta, se.enitic cement, Pozaz la n i cane n t calcium Sulhate comnts; and coment with silica fillarz; may be used in ann~ination 1t h th :1CPOIlYs t rno (or o ther K- .6r density caateria I) insulation b~oards3. M~o reove r a number of Llaturia2O. other c-han caonta could be used. For e::anple, a number of arti -icial resins (relatively high danotty plast1co) ao-ulld he usdIn place of the plaster, ouch aterial in 1iqticd forn could ha poured over the board, while it is tield in a fi1:.ot pooirtIon and allaIred to cover the upper and lower ourfaces the hoard 10, no uell as Its edges if deoired. The art~.ficit r.asin then wwuld be allowed to aet or cure in place, ancaps;Ulatia- the board illustratad %n VIGS 1,3 or 5, the cases may be. Thin comhnitton io very suitable for forning floor and/or roof tiles and thea litthe.

Due to its li-lhtness aind sivt ren ag th, a cor.p osto c h e t according to the present invention hao aI wide range of appltaa titans. Thuo apart from use In or asu ceilings, wall p-caen, Vartttons atc., a composite aheet of the invention can he used as a flooring underlay, wall (Ind cailing inaulation, artistic.

castin or pro-form support, an intaior or excter-ior tile, or roofing mamber, depending on the Selection of Matoriala.

Mloreover, the oholie of the botird aad rusulting shoot could be c~hosen no that a plurality E)f the sheets could ho interlucolt and/or positionod adjacent to otliora of the snue shope, to provide a pleasing appearance ondI provide a modular npproachv to jayin" a ft.oor, linIng a wall or celiang and roofing a buildlin-, For example, a roofing tile 50 Is depicted in Figures 7 to S which incorporates the present invention and which is adapted to interlock to provide a roofing tile system.

There is depicted a composite sheet construction provided with a formed corrugated upper sheet 52 made of, for example, plastic or metal.

The formed sheet 52 is corrugated so that lateral overhanging portion 53 and longitudinal overhanging portion 54 can overlap an adjacent tiles 51A and 518 respectively and cooperate therewith so as to be interlocked with 'tile Corrugated tie 50 depicted in Figure 7 ccmprises an insulation board a high density material such as, for example, calcined gypsum 56, and a corrugated upper sheet 52. Each tile 50, 51A and 518 is generally rectangular with one edge having sheet 52 extending beyond insulation board and high density material 56 to define lateral overhanging portion 53.

Lateral overhanging portion 53 is a semi-cylindrical corrugation which cooperates with corrugation 57 of an adjacent tile 51A to provide a weather-proof connection. An end edge 58 of tile 50 has sheet 52 extending beyond insulation board 55 and high density material 56 to define longitudinal overhanging portion 54 adapted to overlap adjacent tile 51B.

hen tiles 50, 51A and 518 are arranged on an inclined roof structuie 59 (as depicted in Fig. longitudinal overhanging portion 54 overlaps tile 518 so as to provide a weather-proof connection therebetween.

Tile 50 can be attached to roof structure 59 by fasteners Ez and 51 engaging edge projections 62 provided on edge 63 and/or 64 of ttie opposite from longitudinal overhanging portion 54 and the lateral overhanging portion 53, The tiles 50 further comprise recesses 65 disposed so as to receive each projection 62 when tiles 50, 51A and 51B are brought into abutting relationship.

Preferably, the underside of sheet 52 has flat surfaces 66 and semi-circular profiled channels 67 whereby the material 56 filling the channels 67 and the interstices 68 of the Insulation board 55 provides a positive connection therebetween. The undersides of portions 53 and 54 have different profiles which closely cooperate with the top side of the adjacent tiles 51A and 51B.

SARI94T7 9

Claims

1. An article comprising an insulating board having a plt, ',of perforations therein arranged in an array, said board being formed from low density material and having an upper surface and a lower surface, at least one of said surfaces having surface deformations, said deformations including indentations at least laterally spaced from all of said preforatlons and at least one of said surfaces having a plurality of areas of reduced thickness.

2. The article of claim I wherein at least some of said areas of reduced thickness are coincident with said preforations.

3. The article of claim 1 or claim 2, wherein said areas of reduced thickness comprise a plurality of spaced-apart slots in at least one of 0 oI O said upper surface and said lower surface. o °4O0 4. The article of claim 3, wherein said plurality of spaced-apart o:0, cslots comprise a first plurality of slots in said upper surface and a 0 second plurality of slots in said lower surface. The article of claim 4, wherein said first plurality of spaced- 0o apart slots and said second plurality of spaced-apart slots are perpendicular to one another.

6. The article of claim 3, wherein said plurality of spaced-apart slots comprise a first plurality of slots in said lower surface and a oooo second plurality of slots in said lower surface, said first and said second pluralities of slots running perpendicular to one another and being coincident with rows and columns of said array of perforations.

7. The article of claim 6, wherein said plurality of spaced-apart slots further Include a third plurality of slots in said upper surface and a fourth plurality of slots in said upper surface, said third and said fourth pluralities of slots being spaced from the perforations and being perpendicular to one another,

8. The article according to claim 1 or claim 2, including a plurality of semispherical formations arranged in an array on the upper surface and defining interconnected flat areas therebetween, said perforations being in said flat areas.

9. The article according to claim 8, including respective apertures extending through the board from respective apexes of said formations. The article according to claim 9, including respective depressions coaxial to said apertures. F 51 11 i 11. The article according to claim 1 or claim 2, wherein said low density material is polysterene foam.

12. A composite sheet comprising an insulating board having a plurality of perforations therein arranged in a array, said board being formed of low density material and having an upper surface and a lower surface, at least one of said surfaces having surface deformations, said deformations including indentations spaced from said preforations and a plurality of areas of reduced thickness, at least some of which are coincident with said preforations; and a material of higher density than the density of the board applied to at least one of said upper surface and said lower surface and extending through said preforations and filling said deformations.

13. The composite sheet of claim 12, wherein said material of said higher density is also applied to both said upper surface and said lower surface.

14. The composite sheet of claim 13, wherein said material of higher density is also applied to edges of said board encapsulating same. The composite sheet of claim 12, wherein said area of reduced thickness comprise spaced-apart slots, said slots being filled with said material of higher density.

16. The composite sheet of claim 13, wherein said slots are In both the upper surface of said board and said lower surface of said board.

17. The composite sheet of claim 12, wherein said areas of reduced thickness are defined by substantially flat areas, semispherical formations extending from at least one of said upper surface and said lower surface, said material of higher density covering said flat areas and said formations, and wherein said peforations open into said substantially flat areas.

18. The composite sheet of claim 12, wherein said material of higher density is gypsum.

19. The composite sheet of claim 12, wherein said material of higher density is an artificial resin, The composite sheet of claim 12, including a sheet of materlal fixed to at least one of top and bottom of the composite sheet.

21. A composite sheet as defined in any one of claims 12 to 19, including a formed sheet member fixed to a top side thereof. 12 A composite sheet as defined in claim 21 wherein said composite sheet is generally rectangular, and said formed sheet member comprises overhanging portions which project beyond said composite sheet along adjacent edges thereof; and wherein said overhanging portions are adapted to cooperate in overlapping relationship with an adjacent composite sheet.

23. A composite sheet as defined in claim 22, further comprising attachments means to secure said composite sheet to a support means.

24. A composite sheet as defined in claim 23 wherein said attachment means comprises at least one projection provided at an edge of said composite sheet which is distal from said overhanging portions, and fasteners adapted to engage said projections with said support means. A process for producing the composite sheet of any one of claims 12 to 24, comprising providing an insulating board of low density material °i having perforations therein and surface deformations in at least one of its upper surface and its lower surface; and filling the perforations and the 0 deformations with a material so as to cover at least one of said upper surface and said lower surface.

26. An article substantially as hereinbefore described with reference to, and as shown in the accompanying drawings.

27. A composite sheet substantially as hereinbefore described with reference to, and as shown in the accompanying drawings.

28. A process for producing a composite sheet substantially as hereinbefore described with reference to, and as shown in the accompanying drawings. 0 DATED this TENTH day of OCTOBER 1990 oO,, Francisco Andres Cruz Patent Attorneys for the Applicant SPRUSON FERGUSON AYW