CA2146216C - Process for making fibre reinforced cellular cementious building materials - Google Patents

Process for making fibre reinforced cellular cementious building materials Download PDF

Info

Publication number
CA2146216C
CA2146216C CA002146216A CA2146216A CA2146216C CA 2146216 C CA2146216 C CA 2146216C CA 002146216 A CA002146216 A CA 002146216A CA 2146216 A CA2146216 A CA 2146216A CA 2146216 C CA2146216 C CA 2146216C
Authority
CA
Canada
Prior art keywords
cementious
cellular
slurry
integrally formed
mesh
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA002146216A
Other languages
French (fr)
Other versions
CA2146216A1 (en
Inventor
Ramsay Bellingham
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to CA002146216A priority Critical patent/CA2146216C/en
Publication of CA2146216A1 publication Critical patent/CA2146216A1/en
Application granted granted Critical
Publication of CA2146216C publication Critical patent/CA2146216C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00Producing shaped prefabricated articles from the material
    • B28B1/50Producing shaped prefabricated articles from the material specially adapted for producing articles of expanded material, e.g. cellular concrete
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00Producing shaped prefabricated articles from the material
    • B28B1/52Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/02Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material

Abstract

A process for making fibre reinforced cellular cementious building materials. Firstly, mix separately a foam slurry and a cementious mixture containing water and random glass fibres.
Secondly, combine the foam slurry with the cementious mixture in a container to form a cellular cementious slurry containing random glass fibres. The container has a bottom with an orifice positioned adjacent the bottom. Thirdly, pull two parallel spaced layers of integrally formed glass fibre reinforcing mesh through the mixing container filled with cellular cementious slurry and out through the orifice into a drying tray. As the reinforcing mesh passes through the mixing container it pulls along with it cellular cementious slurry.
The orifice restricts the amount of cellular cementious slurry that is drawn into the drying tray, thereby serving to gauge the dimensions of the building material. Fourthly leave the cellular cementious slurry to cure in the drying tray until the cellular cementious slurry has set thereby resulting in a cellular cementious building material having two reinforcing layers of integrally formed glass fibre mesh with random glass fibres extending between the two layers of integrally formed glass fibre mesh.

Description

TITLE OF THE INVENTION:
Process for making fibre reinforced cellular cementious building materials NAME OF INVENTOR:
Ramsay S. Bellingham FIELD OF THE INVENTION
The present invention relates to a process for making fibre reinforced cellular cementious building materials, including all main structural components.
BACKGROUND OF THE INVENTION
International Patent Application PCT/F192/00233 published under the provisions of the Patent Cooperation Treaty March 17, 1994 as International Publication Number WO 94/05605, discloses a fibre reinforced cellular cementious insulation board. The advantages of such material are discussed in the application, namely; light weight, tensile strength along with a thermal insulation capacity. The manufacturing process is not disclosed. The resulting product is soft and consequently, is not capable of being used for structural building components.
The specification of U.K. Patent Application 2,225,599A
published June 6, 1990 discusses a method of producing fibre reinforced cellular gypsum ceiling tile. A highly foamed slurry of gypsum material is poured onto a moving conveyor belt on which is positioned a layer of glass fibre tissue material.
A further layer of glass fibre tissue material is then placed upon the surface of the slurry and passed beneath a gauging device which determines the thickness of the resulting board.
The slurry is then allowed to penetrate the layers of fibrous material before the gypsum material sets. The slurry of consists of gypsum material mixed with water into which air has been entrapped with the help of a surfactant foaming or air-entraining agent. The process employed in the manufacture of such fibre reinforced cellular building materials has an effect on the ultimate quality of the building materials produced.
The U.K. Patent Application contains a warning that vibration of the conveyor belt must be avoided, as it has the undesirable effect of reducing the degree of foaming of the slurry, thereby increasing the density of the product . However, in the absence of vibration there is imperfect penetration of the slurry into the fibrous tissue.
SUMMARY OF THE INVENTION
What is required is a process for making fibre reinforced cellular cementious building materials that will produce building materials capable of being used as structural members .
According to one aspect of the present invention there is provided a process for making fibre reinforced cellular cementious building materials. Firstly, mix separately a foam slurry and a cementious mixture containing water and random glass fibres. Secondly, combine the foam slurry w~_th the cementious mixture in a container to form a cellular cementious slurry containing random glass fibres. The container has a bottom with an orifice positioned adjacent the bottom. Thirdly, pull two parallel spaced layers of integrally formed glass fibre reinforcing mesh through the mixing container filled with cellular cementious slurry and out through the orifice into a curing tray. As the reinforcing mesh passes through the mixing container it pulls along with it cellular cementious slurry.
The orifice restricts the amount of cellular cementious slurry that is drawn into the curing tray, thereby serving to gauge the: dimensions of the building material. Fourthly le~xve the cellular cementious slurry to cure in the curing tray until the cellular cementious slurry has set thereby resulting in a cellular cementious building material having two rei~~torcing layers of integrally formed glass fibre mesh with random glass fibres extending between the two layers of integrally formed glass fibre mesh.
With the process, as described above, the random glass fibres become interconnected with the integrally formed glass fibre mesh to improve the tensile strength of the resulting product. Using the described process materials can be fabricated that will substitute for plywood, drywall, studs, rafters, beams, siding, shingles, shakes, soffits, doors, and strapping. The resulting products can be made with suf:Eicient strength that they are capable of serving as structural members. There is minimal disturbance during processing so the cementious slurry remains highly foamed resulting in a unique combination of light weight and strength. The resulting building materials can be cut, nailed, and otherwise used as wood building materials are currently used. The resulting materials are substantially the same weight as wood and can be used much like wood, but are fireproof and considerably less costly. The building materials can be made, using the described process, out of waste materials such as iJ_y ash, blast furnace slag, silica fume, gypsum, limestone and broken glass. These waste materials are mixed with sand, and cement to form a strong cementious mixture.
According to another aspect of the present invention, there is provided a building material which includes a cellular cementious body having at least two layers of integrally formed glass fibre reinforcing mesh with random glass fibres extending between the at least two layers of integrally formed glass fibre reinforcing mesh. It is preferred that zirconium glass fibres be used.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the invention will be~.orie more apparent from the following description in which reierc~nce is made to the appended drawings, wherein:
FIGURE 1 is a diagrammatic representation of the prorer.r_cc~
process for making fibre reinforced cellular c~:aeentioua building materials.
FIGURE 2 is cutaway perspective view of a b~cr:.i lda_nc~
material made in accordance with the teachings of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A process for making fibre reinforced cellular cementious building materials will now be described with reference to FIGURES 1 and 2.
Referring to FIGURE l, the ingredients selected to be included in the cementious mixture are placed in a 'cur_ntable portioning device 12. As previously described, these ingredients include random glass reinforcing fibres, sznd and cement; together with such materials as fly ash, blas-c furnace slag, silica fume, broken glass, gypsum and limestone. The chosen mixture of ingredients are delivered on a continuous basis to first mixer 14. The steps in the process are as follows: Firstly, mix separately a foam slurry in a second mixer 16 and a cementious mixture containing water and zirconium random glass fibres in first mixer 14. Secondly, combine the foam slurry from second mixer 16 w~_th the cementious mixture from first mixer 14 in a third mixer 17 to form a cellular cementious slurry containing random glass fibres . The contents of third mixer 17 are then discharged into a container 18. Container 18 has a bottom .20 vaith an adjustable orifice 22 positioned adjacent bottom 20. Thirdly, pull two parallel spaced layers of integrally formed ~ ~_r Coil~_11m glass fibre reinforcing mesh 24 and 26 through mixing container 18 filled with cellular cementious slurry and out through adjustable orifice 22 into a curing tray 28. Reinforcing mesh 24 and 26 are pulled by cables 30 and 32, respectively. Cables 5 30 and 32 depend from an overhead loop cable 34 to pull reinforcing mesh 24 and 26 slowly to the end of curing tray 28.
Reinforcing mesh 24 and 26 are fed from feed stock rollers 36 and 38, respectively. Reinforcing mesh 24 engages positioning roller 40 and reinforcing mesh 26 engages a lip 42 of orifice 22 which helps to maintain reinforcing mesh 24 and 26 in parallel spaced relation. As reinforcing mesh 24 and 26 pass through mixing container 18 they pull along with it cellular cementious slurry 44 containing random glass fibres 46 which tend to engage reinforcing mesh 24 and 26. This process is referred to as "pultrusion". Orifice 22 restricts the amount of cellular cementious slurry 44 that is drawn into curing tray 28, thereby serving to gauge the dimensions of the resulting building material. At least one polishing roller 45 is preferably positioned downstream of orifice 22. Polishing roller 45 is also capable of patterning or embossing the resulting product. Fourthly, leave cellular cementious slurry 44 to cure in curing tray 28 until cellular cementious slurry 44 has set.
Referring to FIGURE 2, the process, as described above, results in a building material 48 having a cellular cementious material 44 with two reinforcing layers of integrally formed glass fibre mesh 24 and 26. Random glass fibres 46 extend between glass fibre mesh 24 and 26. A portion of random glass fibres 46 become interconnected with glass fibre mesh 24 and 26 to improve the tensile strength of building material 48.
Referring to FIGURE l, it is preferred that curing tray 28 be equipped with rollers 50 which are positioned on laterally extending rails 52. When one curing tray is filled it can be pushed laterally out of the way to cure, and a second curing tray can be used so the process is disrupted only temporarily to switch trays.
The preferred mixture ( apart from water and ~.~r..r v,='zi.c:h averages 50~ by volume j is blast furnace slag ~0 ~, sar.~cks ~.0° , fly ash 10~, portland cement 5~, silica fume 3~, and rvi_r_-co~.~iurn glass fibres 2~. It is preferred that the cementiour ~n.~_x~~~zre have a low pH level. Curing trays 28 can be pracU;ic:~y.l7_y ~.ry length, approximately 100 yards long is preferred. It ~~,=~J_1 ~:~:
appreciated that the size of orifice 22 determines whether flat boards, or dimension lumber is produced such as 2 x Q., 2 :: 10, etc. Buildings can be constructed with the c:~c:~wca=ib~.d materials . In fact, the process described can proctu.ce ~~.:~.1 ~tlm materials necessary for an entire building constructioxz ~ywer7, including all structural components. The buildings ar_e buil_~t:
by the usual "framing" techniques employed by c~rt?enters accustomed to working with wood. The materials can posi-Lioned in place by screws, nails, and glue and then bonded together in situ by pouring a very light weight short-fibre reinfox=ced cellular concrete into empty wall spaces. The ce=i_l.al~.r concrete not only bonds the building components together, but also serves as insulation and sound proofing. Buildi.nc~:; ~na~~e from the described materials are low cost, as they ui~ilize in large part waste materials, as previously described. The materials can be specially adapted for their intended purposes by adding ingredients to the slurry, adding a step to the process or by subsequent treatment while the product i_s curing in the curing tray. Such treatments include embossing, colouring, and surface hardening by trays, paddle whe:ea_s, or other means.
It will be apparent to one skilled in the arL tha'~
modifications may be made to the illustrated embodiment without departing from the spirit and scope of the invention as hereinafter defined in the Claims.

Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY
OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A process for making fibre reinforced cellular cementious building materials, comprising the steps of:
firstly, mixing separately a foam slurry and a cementious mixture containing water and random fibres;
secondly, combining the foam slurry with the cementious mixture in a container to form a cellular cementious slurry containing random fibres, the container having a bottom with an orifice positioned adjacent to the bottom;
thirdly, pulling two parallel spaced layers of integrally formed fibre reinforcing mesh by means of attached cables through the mixing container filled with cellular cementious slurry and out through the orifice into a curing tray, the reinforcing mesh pulling along with it cellular cementious slurry from the mixing container, the orifice restricting the amount of cellular cementious slurry that is drawn into the curing tray, thereby serving to gauge the dimensions of the building material; and fourthly leaving the cellular cementious slurry to cure in the curing tray until the cellular cementious slurry has set thereby resulting in a cellular cementious building material having two reinforcing layers of integrally formed fibre mesh with random fibres extending between the two layers of integrally formed fibre mesh.
CA002146216A 1995-04-03 1995-04-03 Process for making fibre reinforced cellular cementious building materials Expired - Fee Related CA2146216C (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA002146216A CA2146216C (en) 1995-04-03 1995-04-03 Process for making fibre reinforced cellular cementious building materials

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA002146216A CA2146216C (en) 1995-04-03 1995-04-03 Process for making fibre reinforced cellular cementious building materials

Publications (2)

Publication Number Publication Date
CA2146216A1 CA2146216A1 (en) 1996-10-04
CA2146216C true CA2146216C (en) 2001-08-14

Family

ID=4155564

Family Applications (1)

Application Number Title Priority Date Filing Date
CA002146216A Expired - Fee Related CA2146216C (en) 1995-04-03 1995-04-03 Process for making fibre reinforced cellular cementious building materials

Country Status (1)

Country Link
CA (1) CA2146216C (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6787486B1 (en) 1998-08-26 2004-09-07 Consolidated Minerals, Inc. Backerboard sheet including aerated concrete core
AU767560B2 (en) 1999-10-07 2003-11-13 Consolidated Minerals, Inc. System and method for making wallboard or backerboard sheets including aerated concrete

Also Published As

Publication number Publication date
CA2146216A1 (en) 1996-10-04

Similar Documents

Publication Publication Date Title
EP1228277B2 (en) Wallboard sheet including aerated concrete core
US6221521B1 (en) Non-combustible gypsum/fiber board
US4303722A (en) Building components
EP0943040B1 (en) Wall member and method of construction thereof
US9649662B2 (en) Seamless reinforced concrete structural insulated panel
CA1189719A (en) Building components
US20020090871A1 (en) Cementitious panel with basalt fiber reinforced major surface(s)
US6787486B1 (en) Backerboard sheet including aerated concrete core
CA2146216C (en) Process for making fibre reinforced cellular cementious building materials
AU670272B2 (en) Improved door construction
GB2225599A (en) Cementitious Board
JPS5888156A (en) Manufacture of fiber reinforced lightweight cement formed body
US20040241271A1 (en) Extruder for making a board based on a binder such as gypsum plaster
AU708942B2 (en) Improved door construction
JPH01283137A (en) Light-weight gypsum plate
GB2097837A (en) Building components

Legal Events

Date Code Title Description
EEER Examination request
MKLA Lapsed