EP1102904A1 - Fabrication de panneau de construction - Google Patents

Fabrication de panneau de construction

Info

Publication number
EP1102904A1
EP1102904A1 EP19990936795 EP99936795A EP1102904A1 EP 1102904 A1 EP1102904 A1 EP 1102904A1 EP 19990936795 EP19990936795 EP 19990936795 EP 99936795 A EP99936795 A EP 99936795A EP 1102904 A1 EP1102904 A1 EP 1102904A1
Authority
EP
European Patent Office
Prior art keywords
layer
surface layers
layers
building board
core layer
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Withdrawn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
EP19990936795
Other languages
German (de)
English (en)
Inventor
Stuart Edward Horsley
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.)
BPB Ltd
Original Assignee
BPB Ltd
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 BPB Ltd filed Critical BPB Ltd
Publication of EP1102904A1 publication Critical patent/EP1102904A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B28B1/522—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement for producing multi-layered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B28B1/526—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement by delivering the materials on a conveyor of the endless-belt type
    • 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
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/049—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres completely or partially of insulating material, e.g. cellular concrete or foamed plaster
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00241—Physical properties of the materials not provided for elsewhere in C04B2111/00
    • C04B2111/00413—Materials having an inhomogeneous concentration of ingredients or irregular properties in different layers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00905—Uses not provided for elsewhere in C04B2111/00 as preforms
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the present invention relates to the production of building board of superior strength, Modulus of Rupture (MOR) , Limit of Proportionality (LOP) and stiffness, which make it suitable for use in load-bearing situations, for example in suspended flooring.
  • MOR Modulus of Rupture
  • LOP Limit of Proportionality
  • stiffness which make it suitable for use in load-bearing situations, for example in suspended flooring.
  • the invention relates to an improvement in layered gypsum fibre board having surface layers formed from compositions having lower water : plaster ratios than used in the production of traditional plasterboard from aqueous slurries of gypsum plaster.
  • Gypsum fibre board of this kind and a semi-dry method of manufacturing it have been described in International Patent Publication WO93/01932 of Carl Schenck AG.
  • a building board comprises cementitious fibre board comprising first and second surface layers of fibres admixed with cementitious material; a core layer of a structural solid additive, such as fibres or lightweight aggregate, admixed with cementitious material but of different composition from either of the surface layers and disposed between the surface layers and bonded thereto by interpenetrating crystal growth; at least one layer of fibrous mesh being interposed between the core layer and at least one of the surface layers and bonded to each of the adjacent layers by the interpenetrating crystal growth.
  • a structural solid additive such as fibres or lightweight aggregate
  • the board of this invention may be produced by preparing a mix or mixes containing fibrous or structural solid material, as the case may be, hydratable cementitious material and water to constitute the surface layers and core of the product; spreading a layer of a surface mix on a supporting surface; and thereafter successively spreading layers of the core mix and a surface mix to form a fibrous cementitious assembly; compressing the assembly to a predetermined thickness; and maintaining the pressure until hydration of the cementitious material in the assembly is substantially complete; in which at least one layer of fibrous mesh is interposed between at least one pair of adjacent layers of the mixes during formation of the assembly.
  • the cementitious material is preferably gypsum
  • the surface layers are preferably produced from semi-dry compositions having lower water: plaster ratios than those used in the manufacture of traditional plasterboard, which are slurries and require to be handled differently.
  • such slurry compositions have water: plaster ratios in excess of 60%
  • the compositions used to form the surface layers preferably have water: plaster ratios below 58%, and especially in the range 50-55% by weight.
  • the core layer may contain up to 20% fibre, calculated on the dry weight of the core layer in the finished board. Whether or not it includes fibre, the core should always contain sufficient structural solid additive to provide a semi-dry mix when admixed with the cementitious material and hydration water.
  • the additive referred to here is a solid material capable of conferring a physical structure on the layer when bonded by the cementitious material, and is typified by fibrous materials and aggregates, notably lightweight aggregates.
  • the fibres in the layers may be cellulose fibres, such as paper or wood fibres.
  • the fibre contents of the layers may differ from one another, the core layer preferably having a lower fibre content than the surface layers.
  • the core may contain from 0 to 20% paper fibre and typically about 8%
  • the surface layers may contain from 5 to 20% paper fibre on the same basis, values about 14% being typical.
  • the core layer preferably has a lower density than the surface layers.
  • the layers, but more especially the core layer may additionally contain a lightweight aggregate, such as conventionally expanded perlite vermiculite or the like. Suitable levels of such aggregate are from 10% to 60%, for example about 30%, perlite by weight of the layer in the finished board.
  • the water necessary for the hydration and setting of the cementitious binder material can be introduced to the mix wholly or in part as water absorbed in the fibrous constituent of the mix. Water can also be introduced, more especially into the core mix, by the use of wet or damp lightweight aggregate material. Any shortfall in the water necessary for hydration can be made up by a separate addition or by spraying the layers or assembly with water.
  • the fibrous mesh may be of inorganic fibre such as glass or carbon fibre, or of organic fibres, such as polypropylene or high density oriented polyethylene. Not only may one or more layers of, for example, inorganic fibrous mesh be interposed between one or both surface layers and the core layer, but one or more layers of organic fibrous mesh may additionally be interposed in either or both of these locations.
  • a glass fibre mesh may be included to increase stiffness and an organic mesh to improve impact properties.
  • the fibrous mesh may be of glass fibres and preferably takes the form of an open mesh glass fibre fabric or crenette.
  • the open texture of the fabric helps the compositions of the two adjacent layers to combine during the pressing operation.
  • the size of opening of the mesh is preferably from 1.0 to 20mm, a typical crenette having about 8 tows per inch (about 3 per cm) .
  • the support surface may be a moving belt or table in a continuous production line, and the board, after release from pressure, may be cut into lengths before being dried. Pressure may be varied at different times during the process, or at different positions along the line, to provide a pressure profile that encourages combination of the layers and fibrous mesh.
  • the thickness of the various layers in the board can be adjusted by varying the amount and thus the thickness of the respective compositions spread on the support surface. By this means the relative thickness of each of the surface and core layers in relation to the others can be adjusted. This in turn enables the distance of the one or more layers of fibrous mesh from the central plane of the board to be controlled.
  • compositions may contain other substances, including additives well known in the production of building board.
  • the compositions may contain setting accelerators to enable the setting and hydration times of the compositions to be adjusted to suit the particular product or circumstances of production. This is in addition to the presence in one or more of the layers, and especially in the core layer, of an aggregate, for example a lightweight aggregate such as expanded perlite.
  • the compositions may also include a viscosity modifier.
  • the proportion of water in the mixes should be kept low, provided the total quantity of water applied during manufacture is at least stoichiometrically sufficient.
  • the mixes will therefore have a semi-dry rather than a flowable consistency, and the pressure regime must be adjusted to ensure that the fibrous mesh is firmly embedded between the compressed layers of the board.
  • a fibrous mesh is introduced into an assembly of gypsum fibre layers for the manufacture of layered gypsum fibre board by this kind of semi-dry process.
  • Fig. 1 is a schematic view of one example of a line for producing board in accordance with this invention.
  • Fig.2 is a cross-section of one example of board embodying the invention.
  • wet recycled paper fibres for a bottom surface layer are spread on a first preforming belt 10, followed by a layer of hemihydrate plaster together with additives.
  • the belt 10 carries the materials to a mixing head 11, which deposits the resulting mix on a main forming belt 12.
  • glass fibre crenette is drawn from a roll 13 and laid over the bottom surface layer on the main belt 12.
  • Wetted aggregate and fibres for the core mix are supplied to a blender 14, from where it is spread on a second pre-forming belt 15, passing through a mixing head 16 to be spread on top of the bottom surface layer and crenette on the main forming belt 12.
  • a blender 14 from where it is spread on a second pre-forming belt 15, passing through a mixing head 16 to be spread on top of the bottom surface layer and crenette on the main forming belt 12.
  • fibres and plaster for a top surface layer are supplied to a third pre-forming belt 17 are mixed in a mixing head 18 and spread on top of the core layer on the main forming belt.
  • the assembled layers pass into the press 19 where pressures are applied according to a profile which ensures that the mixes set together and incorporate the crenette into the crystal structure of the product.
  • the pressures applied to mixes are controlled such that the dry finished board has a density in the range 350kg/m 3 to 1350kg/m 3
  • the assembly leaves the press region and is trimmed and cut into lengths for drying.
  • the product exhibits the structure shown in Fig. 2, and comprises a bottom surface layer 20 of gypsum with a relatively higher fibre content, for example of paper fibres, a core layer 21 of gypsum with a lower fibre content, and preferably containing a lightweight aggregate such as perlite, a web of inorganic fibrous mesh 22, such as the glass fibre crenette already discussed, and an upper surface layer 23 of gypsum with a higher fibre content, which may have the same composition as the bottom surface layer, or different, depending on the properties required of the board.
  • Board in accordance with the invention may be made with two smooth surfaces. It can, depending on its composition and density, exhibit a flexural strength up to 15 MPa or more.
  • Fig. 1 If it is required to manufacture board with more than one layer of fibrous mesh between the core layer and one or both surface layers, or with a layer or layers of organic fibrous mesh in addition to an inorganic fibrous mesh in either or both of these positions, the apparatus shown in Fig. 1 can be modified to provide the necessary additional supply rolls 13 for other fibrous meshes, which are led between the appropriate mixing heads 11, 16 or 18.
  • Fibrous mesh can also be applied externally during formation of the assembly, either before the mixing head 11 or after the mixing head 18, but the resulting product may not have smooth surfaces.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Civil Engineering (AREA)
  • Laminated Bodies (AREA)
  • Panels For Use In Building Construction (AREA)

Abstract

L'invention concerne un panneau de construction constitué d'un aggloméré à base de ciment. Ce panneau comporte une première et une seconde couche de surface (20, 23) de fibres mélangées à du ciment ; une couche centrale (21) de fibres mélangées à un matériau à base de ciment mais de composition différente de celle des deux couches de surface, cette couche étant disposée entre les couches de surface et liées à celles-ci par tirage de cristal pénétrant ; et au moins une couche de mailles fibreuses (22) placées entre la couche centrale et au moins une des couches de surface, et liée à chacune des couches adjacentes par tirage de cristal pénétrant. On peut fabriquer le panneau selon l'invention en étalant successivement des mélanges centraux et de surface, de façon à former au moins deux couches adjacentes de ces mélanges, en donnant par compression une épaisseur déterminée à l'ensemble, puis en maintenant la pression jusqu'à ce que l'hydratation du matériau à base de ciment compris dans l'ensemble soit sensiblement achevée.
EP19990936795 1998-07-28 1999-07-28 Fabrication de panneau de construction Withdrawn EP1102904A1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
GB9816427A GB9816427D0 (en) 1998-07-28 1998-07-28 Building board and its production
GB9816427 1998-07-28
PCT/GB1999/002472 WO2000006849A1 (fr) 1998-07-28 1999-07-28 Fabrication de panneau de construction

Publications (1)

Publication Number Publication Date
EP1102904A1 true EP1102904A1 (fr) 2001-05-30

Family

ID=10836315

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19990936795 Withdrawn EP1102904A1 (fr) 1998-07-28 1999-07-28 Fabrication de panneau de construction

Country Status (4)

Country Link
EP (1) EP1102904A1 (fr)
GB (1) GB9816427D0 (fr)
PL (1) PL345668A1 (fr)
WO (1) WO2000006849A1 (fr)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT1309463B1 (it) * 1999-03-31 2002-01-23 Impresa Marinoni S R L Prodotto e procedimento per un'isolazione tagliafuoco.
US11339572B1 (en) 2017-01-23 2022-05-24 Gold Bond Building Products, Llc Method of manufacturing gypsum board with improved fire
US20230021340A1 (en) * 2021-07-09 2023-01-26 United States Gypsum Company Board with fiber-reinforced dense layer

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB8825747D0 (en) * 1988-11-03 1988-12-07 Bpb Industries Plc Cementitious board
US4868039B1 (en) * 1988-12-29 2000-04-25 Caribank Structural panel incorporating glay grog and vermiculite and method for making said panel
DE3937433A1 (de) * 1989-11-10 1991-05-16 Knauf Westdeutsche Gips Gipsbauplatte mit kaschierungen aus beschichteten glasfaservliesen und verfahren zur herstellung derselben
DE4107623C2 (de) * 1991-03-09 1997-09-04 Knauf Westdeutsche Gips Gipsplatte mit hohem Feuerwiderstand
DE4222872C2 (de) * 1991-08-09 1996-01-25 Siempelkamp Gmbh & Co Dreischichtige Baustoffplatte auf Gipsbasis und Verfahren zur Herstellung
DE4142286C2 (de) * 1991-12-20 1995-01-05 Siempelkamp Gmbh & Co Dreischichtige Baustoffplatte auf Gipsbasis und Verfahren zur Herstellung
ES2158923T3 (es) * 1994-09-15 2001-09-16 Knauf Westdeutsche Gips Placa de construccion de yeso con capa de napa de vidrio revestida.
GB2316693B (en) * 1996-08-29 2000-05-31 Bpb Plc Building board

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO0006849A1 *

Also Published As

Publication number Publication date
WO2000006849A1 (fr) 2000-02-10
GB9816427D0 (en) 1998-09-23
PL345668A1 (en) 2002-01-02

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