EP0597982A1 - Structure composite a noyau en mousse et procede de production - Google Patents

Structure composite a noyau en mousse et procede de production

Info

Publication number
EP0597982A1
EP0597982A1 EP92917038A EP92917038A EP0597982A1 EP 0597982 A1 EP0597982 A1 EP 0597982A1 EP 92917038 A EP92917038 A EP 92917038A EP 92917038 A EP92917038 A EP 92917038A EP 0597982 A1 EP0597982 A1 EP 0597982A1
Authority
EP
European Patent Office
Prior art keywords
core
outer layer
composite material
lightweight
composite
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.)
Withdrawn
Application number
EP92917038A
Other languages
German (de)
English (en)
Other versions
EP0597982A4 (fr
Inventor
Jeff S. Sweeney
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.)
Diversitech Corp
Original Assignee
Diversitech Corp
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 Diversitech Corp filed Critical Diversitech Corp
Publication of EP0597982A4 publication Critical patent/EP0597982A4/fr
Publication of EP0597982A1 publication Critical patent/EP0597982A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/02—Layered 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered 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
    • B32B5/18—Layered 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B13/045—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/302—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/558—Impact strength, toughness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2325/00—Polymers of vinyl-aromatic compounds, e.g. polystyrene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Definitions

  • the present invention generally relates to a composite structural material and the method of making the same and more specifically the invention relates to a low cost, lightweight, fire resistant composite material and the method of making the same in which the composite consists of a core constructed from lightweight expanded foam plastic such as expanded polystyrene.
  • the core is covered on one or more of its surfaces with a high strength outer layer constructed of a layer or layers of non-woven fabric webs impregnated or infiltrated with cementitious slurry binder with the fibers in the layers of non-woven fabric material forming a three-dimensional reinforcement matrix for the cementitious slurry.
  • the outer layer is formed and cured on one or more surfaces of the lightweight plastic core resulting in a crack resistant outer layer having greater ductility and toughness than ordinary cement or concrete.
  • the cement in the outer layer bonds directly to the lightweight plastic core thus requiring no additional bonding agent.
  • Outer layers can be formed and cured around various shaped cores for various end uses.
  • Composite materials comprised of high strength outer layers bonded to lightweight core materials are utilized for several applications.
  • the outer layers serves to increase the strength, durability, ultra ⁇ violet resistance, fire resistance, chemical resistance, or combinations of these properties of the composite depending on the application.
  • Patent No. 4,764,238 discloses a composite material made by applying heat and pressure to fabrics preimpregnated with a thermosetting resin to bond the fabrics to an open-celled foam core. The resulting lightweight composite is claimed to be suitable for energy absorbing, impact-resistant structures.
  • Patent 4,050,659 relates to an electrical transformer equipment pad made with a fiberglass reinforced exterior plastic surface formed around an expanded foam core.
  • Patent 4,303,722 describes a panel constructed of thin facings, comprised of a fabric or web of glass fibers and a set composition of thermosetting condensation resin and gypsum, bonded to a rigid substrate such as a foamed plastic material.
  • the fibers in the reinforcing material are essentially two-dimensional, advantageously placed as near to the surface of the facing as possible.
  • Patent 4,963,408 relates to a unitary composite laminate structure made by encapsulating a foam core with a load bearing polymer matrix reinforced with oriented fibers. This composite also utilizes a bonding material to fuse the outer layer to the core.
  • Patent 4,559,263 described a cement-foam composite board in which a concrete, made with lightweight aggregate and a foaming agent is bonded on one side of an expanded foam panel. This patent further claims that an unspecified reinforcing means may be included in the concrete.
  • Non-woven webs of fibers have been utilized as reinforcement for cement matrices for thin sheet-like materials.
  • Patent 4,778,718 refers to a non-woven reinforced cement sheet made by screeding dry cement into the fiber matrix and then applying water to hydrate the cement and form a sheet.
  • Patent 4,617,219 relates to a three- dimensionally reinforced cement structure utilizing at least one non-woven web as the fibrous reinforcement. This patent further claims that layers of such non- woven reinforced cement sheets can be formed together to produce structural panels.
  • the thin, core- less sheets do not exhibit insulative properties significantly greater than those of ordinary concrete.
  • Blocks of lightweight, foamed plastic such as polystyrene
  • buoyant support of floating structures such as boat docks.
  • chemicals in the water, from outboard motors, for example can break down the block and pieces of the block are then free to pollute the body of water.
  • SUMMARY OF THE INVENTION It is the object of the present invention to provide a lightweight, low cost, ductile and crack- resistant composite material which also possesses fire resistance.
  • a further object of this invention is to provide a method of manufacture of this composite in suitable forms to meet such end uses as equipment pads, floating docks, building panels, noise abatement surfaces, and fire resistant self-cladded insulation.
  • the composite consists of a high strength outer layer formed and cured around one or more sides of a lightweight core.
  • This outer layer is a cementitious matrix three-dimensionally reinforcedwith a non-woven web of fibers.
  • the fibers are present in
  • the fibers are completely encapsulated in the cement matrix, giving the outer layer the appearance, hardness, and durability of ordinary concrete.
  • the fibers are also protected from fire and ultra-violet radiation by the cement matrix.
  • This outer layer is applied to the core, preferably expanded polystyrene, while the cement matrix is in its wet, uncured form.
  • the outer layer can be applied by hand or by mechanical pressing means to insure that the wet cement matrix is uniformly distributed throughout the fiber web and evenly in contact with the lightweight core to allow the outer layer to bond to the core as the cement matrix cures.
  • the use of a lightweight, foamed plastic core gives the composite material a high strength:weight ratio. This is true in flexure due to the beam design of the sandwich panel and the high flexural strength of the outer layer. In compression, the composite exhibits high strength due to the outer layer's compressive strength, which is equivalent to ordinary concrete.
  • the outer layer of the composite first protects the polystyrene core from attacking chemicals and further prevents pieces of the plastic core from breaking away and polluting the marine environment.
  • Figure 1 is a perspective view of a panel utilizing the composite structural material of the present invention.
  • Figure 2 is a sectional view, on an enlarged scale, illustrating the specific arrangement of the components forming the composite structural material of this invention.
  • Figure 3 is a perspective view of a buoyant support for a floating structure such as a boat dock.
  • a composite structural component in the form of a panel is illustrated in Fig. 1 and generally designated by reference numeral 10 and which includes a core generally designated by reference numeral 12 and an outer layer generally designated by reference numeral 14 which may extend over one surface of the panel, both opposed surfaces or around all of the edges and all of the surfaces.
  • the outer layers 14 form the interior and exterior surfaces of the panel and they can be textured or colored when being formed or finished with various materials such as plastic, sheathing, painting, grooving or the like for appearance purposes to enable any desired architectural finish characteristics to be obtained.
  • the core 12 is constructed of lightweight foam plastic such as expanded polystyrene in the form of a board 16, block or other structural entity.
  • the outer layer 14 includes a three- dimensional web of non-woven web 18 which includes non- woven fibers 20 in which the fiber volume ranges between 3 and 20%.
  • a cementitious slurry binder 22 intimately surrounds, infiltrates and connects the fibers 20 when the cementitious slurry binder is cured.
  • the cementitious slurry binder 22 in the outer layer is cured with the cured and hardened slurry binder 22, outer layer 14 and non-woven fibers 20 and core 12 becoming a rigid, integral body thus providing a panel with an ultra lightweight core which is reinforced and rigidified by the outer layer or layers with the core and layer or layers being rigidly formed into a single rigid unit.
  • a panel was formed in accordance with the present invention by providing an expanded polystyrene board 16.
  • a cement slurry was mixed in a portable mortar mixer with the following ratios by weight: 10 parts Portland cement,
  • Sheets of a non-woven web material in the form of a needlepunched polypropelene weighing 8 ounces per sq. yd. with a loft of 1/4" were cut into pieces of appropriate size to cover the board and applied to the core after the cement slurry has been applied in its wet uncured form by hand or mechanical press.
  • test beams were cut from the panel with the test beams being 24" in length, 6" wide and 21/2" thick. These test beams were tested for flexural strength after a 7 day curing period by using 3rd point loading on an 18" span with the average flexural strength being 500 psi. This flexural strength is approximately equivalent to prior art panels when constructed to be 4" thick which weigh approximately 20 pounds per sq. ft.
  • the lightweight, low cost, insulative, fire resistant, chemical resistant, ultra-violet resistant and ductile structure enables the composite material to be used as an equipment supporting base or pad, fire resistant noise abatement panels, building panels, self-cladded insulation for pipe and ductwork and a float to support a dock with the composite structural material providing adequate buoyancy to floatingly support the dock at a desired elevation in relation to the water and having a high resistance to ultra-violet light deterioration.

Landscapes

  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

On décrit un matériau de structure composite ainsi que le procédé de production à faible coût d'un matériau composite léger, malléable, durable et ayant une résistance à la fissuration, constitué d'un noyau (12) produit à partir d'une mousse légère expansée. Le noyau est enrobé sur un ou plusieurs de ses côtés d'une couche extérieure très résistante (14) fabriquée à l'aide d'une couche comprenant des couches de matériaux fibreux non tissés sous forme de bandes imprégnées d'un liant en pâte épaisse scéllant (22), les fibres présentes dans les couches de la bande de matériau non tissé formant une matrice de renforcement tridimensionnelle (18) pour la pâte épaisse. La couche extérieure est formée et séchée sur une ou plusieurs surfaces du noyau en mousse légère se traduisant par une couche extérieure ayant une résistance à la fissuration et possédant une malléabilité et une robustesse accrue par rapport au ciment ou béton ordinaire. Le ciment se trouvant dans la couche extérieure adhère directement au noyau en mousse légère ne nécessitant pas ainsi un agent de liaison supplémentaire. Les couches extérieures peuvent être formées et séchées autour de noyaux de diverses formes en vue de différentes utilisations finales.
EP92917038A 1991-07-22 1992-07-22 Structure composite a noyau en mousse et procede de production Withdrawn EP0597982A1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US73363191A 1991-07-22 1991-07-22
US733631 1991-07-22
PCT/US1992/005978 WO1993001931A1 (fr) 1991-07-22 1992-07-22 Structure composite a noyau en mousse et procede de production

Publications (2)

Publication Number Publication Date
EP0597982A4 EP0597982A4 (fr) 1994-03-16
EP0597982A1 true EP0597982A1 (fr) 1994-05-25

Family

ID=24948459

Family Applications (1)

Application Number Title Priority Date Filing Date
EP92917038A Withdrawn EP0597982A1 (fr) 1991-07-22 1992-07-22 Structure composite a noyau en mousse et procede de production

Country Status (5)

Country Link
EP (1) EP0597982A1 (fr)
JP (1) JPH07500058A (fr)
AU (1) AU2404392A (fr)
CA (1) CA2113834A1 (fr)
WO (1) WO1993001931A1 (fr)

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2722223B1 (fr) * 1994-07-06 1996-09-20 Daussan & Co Article moule pour la protection anti-feu
DE19549534C2 (de) * 1995-01-30 1999-07-08 Harald Hagedorn Bauelement mit Schichtaufbau
ES1034840Y (es) * 1996-08-01 1997-07-01 Pellicer Carlos F Panel para cerramiento interior de edificaciones.
US20040043682A1 (en) * 2002-09-04 2004-03-04 Taylor Steven L. Composite board
WO2006116842A2 (fr) 2005-04-29 2006-11-09 Woodbridge Foam Corporation Produit stratifie de mousse et son procede de production
CN101845874A (zh) * 2010-06-02 2010-09-29 霍伟生 一种新型外墙高效节能保温装饰板
JP6910777B2 (ja) * 2016-09-28 2021-07-28 ニチハ株式会社 建材の製造方法
RU2743743C2 (ru) * 2016-09-28 2021-02-25 Нитиха Корпорейшн Строительный материал и способ получения строительного материала
JP6910778B2 (ja) * 2016-09-28 2021-07-28 ニチハ株式会社 建材の製造方法

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3745058A (en) * 1967-10-31 1973-07-10 Saint Gobain Building material and method of making it
CA1141640A (fr) * 1979-06-08 1983-02-22 Thomas A. Pilgrim Elements de construction
GB2136468A (en) * 1983-03-05 1984-09-19 Beasey Eric Composite tile
US4617219A (en) * 1984-12-24 1986-10-14 Morris Schupack Three dimensionally reinforced fabric concrete

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
No further relevant documents disclosed *
See also references of WO9301931A1 *

Also Published As

Publication number Publication date
AU2404392A (en) 1993-02-23
WO1993001931A1 (fr) 1993-02-04
EP0597982A4 (fr) 1994-03-16
JPH07500058A (ja) 1995-01-05
CA2113834A1 (fr) 1993-02-04

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