Classifications

• • 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
  • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
• • 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
  • B28B1/14—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted
  • B28B1/16—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted for producing 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
  • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
  • C09J5/00—Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers

Definitions

• This invention relates to a method of forming a composite body by binding together a pair of first and second bodies.
• a pair of solid first and second bodies of the same material or different materials may be bound together by means of a glue, an adhesive or any other kind of binding material. This is conventionally done by forming a pair of substantially complementary surface parts on such bodies, applying adhesive or binding material to at least one of the complementary surface parts and thereafter pressing the complementary surface parts together.
• the complementary surface parts may be obtained by moulding or casting said second body against a first surface part of the first body which is made from a solid or solidified material. In such case, where the first body is used as a mould surface or mould part when moulding or casting the second body from a material different from that of the first body, it is quite often not possible to obtain a bond between the bodies which is able to transfer sufficiently large tensile and shear stresses.
• This known method is rather complicated and time consuming. Furthermore, in many situations this known method of applying binding material or adhesive to the complementary surface parts can not be used, for example when the first and second bodies are extremely heavy and/or when the first body is partly or totally embedded within the second body, which has been moulded or cast around he first body.
• the present invention relates to a method of forming such composite body in a new way.
• the method also enables the production of composite bodies wherein two solid bodies having quite different properties, for example different coefficients of expansion or different toughness, may be joined via a compliant intermediate binding body.
• the present invention provides a method of forming a composite body comprising a pair of first and second solid bodies and an intermediate body binding the first and second bodies together, said method comprising arranging a spacing member defining the outer surfaces of the intermediate binding body such that a first surface part of the spacing member is in engagement with an adjacent surface of the first body, forming the second body in a deformable condition against and in contact with a second surface part of the spacing member opposite to said first surface part, solidifying said second body, and converting the spacing member into said intermediate binding body while maintaining the first and second bodies in their mutual position.
• the first body may be preformed in the required shape or it may be formed as part of a sequential method according to the invention whereby the first body is formed and the spacing member is then arranged as specified above prior to carrying out the other steps of the method.
• the spacing member is converted into the intermediate binding body. Such conversion is performed without substantially changing the mutual position of the first and second bodies.
• conversion of the spacing member to the intermediate binding body results in some slight expansion or shrinkage, methods are available as discussed below to minimise relative displacement of the two bodies.
• the method according to the invention may be used not only when the first and second bodies have a size and shape which would have allowed application of an adhesive or a binder in a conventional manner, but also when the first and second bodies are so large and heavy that they are difficult or impossible to separate and reposition and/or when the first body is at least partly embedded in or surrounded by the solidified second body.
• the spacing member may consist of or comprise a binding material which is inactivated or which has simply not yet developed its active binding property, and its conversion may include activating said binding material or allowing the binding material to develop its binding property so as to bind the first and second bodies together by the binding material.
• a binding material which has not yet developed its active binding property is a fluid two-component adhesive after its two components have been mixed, but before the reaction between the two components has proceeded to such an extent that the adhesive has cured.
• Activation of inactivated binding material may for example comprise heating, melting, irradiating or otherwise curing the inactivated binding material or application of a solvent or a binder component or binder activator in a fluid state, such as a liquid or gaseous state, etc.
• the spacing member may define one or more inner cavities therein for receiving such solvent or binder component or binder activator.
• the binder eventually solidifies and forms together with possible parts of the spacing member not being binder components the solidified intermediate body.
• the spacing member may consist entirely of inactivated binder, which is converted to the intermediate binding body by curing after solidification of the second body, or it may comprise parts not being components of the binder.
• the spacing member may be a non-binding structure which intrinsically or together with the first and second surface parts of the first and second bodies may define one or more cavities containing, or for receiving, inactivated binder. Conversion of the spacing member to intermediate binding body is then achieved by introducing a not yet cured binder, such as a two component epoxy, polyurethane or acrylate/acrylonitrile adhesive, into such cavities (if not already present) and curing the composite of non- binding structure and binder.
• a not yet cured binder such as a two component epoxy, polyurethane or acrylate/acrylonitrile adhesive
• the spacing member must be adapted to allow and secure such contact.
• the binder may be caused via said cavity or cavities to come into contact with said opposite first and second surface parts of the spacing member and the adjacent surface parts of said first and second bodies engaging therewith, whereby the desired strong bond may be obtained.
• the said second surface part of the spacing member against which the second body is formed in a deformable condition should be of a structure sufficiently tight to prevent the casting material of the second body from penetrating into possible inner cavities of the spacing member.
• the said first and second surface parts of the spacing member may have a plurality of small openings defined therein communicating with the cavity or cavities of the spacing member.
• the spacing member may define a porous matrix structure.
• the spacing member may include one or more curing components of the binder or binder component being introduced.
• the spacing member may be formed partly or exclusively by one or more components of a binder composition requiring a counterpart component for activation being of a porous or cellular structure, and the binder may then be activated by injecting as a fluid or gaseous binder counterpart into the pores or cells of the spacing member.
• the spacing member may be made from a substance or material which may be totally or partly removed, for example by heating it to a melting or evaporation temperature, or the spacing member may be made from a material and/or have a form allowing reduction of its volume when exposed to a treatment, such as a heat treatment.
• the spacing member may be hollow or porous so as to collapse when exposed to heat.
• Each of the first and second bodies may be made from any suitable material, such as metals, metal alloys, plastics or plastics-based materials, wood, glass, gypsum, solidified, including frozen, liquids, ceramics, including chemically bonded ceramics such as cement paste, mortar or concrete, and including any of the above-mentioned materials when they are fibre-reinforced.
• suitable material such as metals, metal alloys, plastics or plastics-based materials, wood, glass, gypsum, solidified, including frozen, liquids, ceramics, including chemically bonded ceramics such as cement paste, mortar or concrete, and including any of the above-mentioned materials when they are fibre-reinforced.
• DSP-materials DSP-materials
• DSP Densified Systems containing ultrafine Particles
• Said first body may be a reinforcing member and the spacing member may be positioned in contact with the reinforcing member.
• the second body may then be formed by casting a pourable, solidifiable material in contact with the spacing member.
• the first body may be made from steel or a steel alloy and the second body may be made from a hardened concrete or a DSP-material.
• the binding material may be selected such that maximum forces or stresses may be transferred between the first and second bodies or between the reinforcing members and the material of the body in which they are embedded even when the reinforcing members have relatively smooth outer surfaces.
• the material of the intermediate body may bridge such different characteristics and secure good bonds between the intermediate body and the first and second bodies, respectively.
• the principle of the invention thus can be used to provide a compensating interface between bodies of widely different characteristics, such as in the bonding of reinforcement to chemical bonded ceramics.
• the resiliency of the material of the intermediate body could be sufficient to accommodate a possible difference in coefficient of thermal expansion of the materials forming the first and second bodies, respectively.
• the method according to the invention may be used for making a mould or tool part.
• the first body may a layer having an outer surface with a desired shape and this layer may then form the active surface or working surface of the tool or mould part.
• the said layer may consist of or include a layer of metal for example formed by spray metal, vapour deposition or galvanic techniques, synthetic plastics material, or Gelcoat - ie a hard plastics layer formed by coating a curable resin onto a pattern previously coated with release agent.
• the second body which may be made by casting high strength concrete or DSP-material forms a body member or backing up member of the mould or tool part.
• the shaped metal layer may be made in different ways. As an example, a shaped metal layer may be made from a blank of sheet metal, such as stainless steel, which may be given the desired shape by punching and/or drawing.
• the shaped metal layer may be formed by galvanic or electrolytic precipitation on a surface of a sample having the shape desired.
• one of the first and second bodies may be formed from a substance in vapour form, such as by chemical vapour deposition, or by a substance in the form of ions in liquid phase, such as metal forming by galvanic technique.
• a tool part thus made may be a drawing tool part for drawing a specific article from a sheet metal blank, and in such case the shaped metal layer may be precipitated on an outer surface part having a shape complementary to the desired shape of said specific article to be produced.
• the surface part on which the metal layer is formed by galvanic or electrolytic precipitation or vapour deposition is advantageously a surface part of a sample of the specific article to be produced, for example a spare part of a car body.
• a mould part produced in a manner described above may, for example, be part of a mould for blow moulding, sheet moulding, resin transfer moulding, glass mat thermoplastics moulding, injection moulding, or vacuum moulding.
• Particular uses include as part of a blow mould for blow moulding plastic material, of an injection mould for moulding articles from plastics or metal, or as a compression mould for compressing a powdered or particulate material for forming an article therefrom.
• Such compression mould could be used for compressing and possibly sintering metallic particles or for forming and/or compressing concrete or a DSP-material so as to produce tiles, roof plates, or any other articles made from such materials, or other compressed powdered or particulate materials.
• One or more passages for introducing liquid uncured binder into a cavity or cavities of the spacing member may be formed in first and/or the second body.
• one of the said first and second bodies is partly or completely surrounded by the other. This means that the space, which is defined between the first and second bodies and which contains the spacing member is not directly accessible.
• one or more passages for introducing the liquid binder into the cavity or cavities of the spacing member may be formed in the outer one of the first or second bodies.
• a spacing member having cavities for introduction of inactivated binder as discussed above may have a mesh or a chain mesh structure, or may be formed from non-woven fabrics.
• Examples include steel mesh, steel chain mesh, fiber mat such as glass fiber or carbon fiber mat, and non-woven fiber fabrics such as polypropylene or polyester fiber fabrics.
• Compression resistant spacing members such as those formed from steel chain mesh are advantageous for those applications where shrinkage of the spacing member during conversion to the intermediate binding body is to be resisted.
• Steel mesh or glass mats also have a degree of thickness- wise rigidity which helps minimise the effects of shrinkage.
• Non woven fabrics are advantageous where the intermediate binding layer is required to be compliant to small amounts of shear displacement between the first and second bodies.
• spacing member structure In general, the choice of spacing member structure will in part be dependent on the properties required of the finished bonded article. In some cases a spacing member consisting of one or more type of material may be preferred, for example a layer of mesh material with a layer of non- woven fabric abutting the second body.
• the binder at least partly forming the intermediate binding body may tend to shrink or expand when solidifying.
• this tendency may endanger the efficiency of the bond being formed between the first and second bodies.
• a super atmospheric pressure may be applied to the binder introduced in the cavity or cavities before the binder is solidified. Preferably, such super atmospheric pressure is maintained till the binder has solidified.
• the liquid or gaseous binder or binder component may be supplied to a cavity or cavities of the spacing member in any known manner, for example by means of an external pressure source, such as a compressor, a pressure cylinder, or the like, or by sucking the binder into the cavity or cavities by reducing the ambient pressure in the vicinity of the spacing member (vacuum techniques).
• an external pressure source such as a compressor, a pressure cylinder, or the like
• sucking the binder into the cavity or cavities by reducing the ambient pressure in the vicinity of the spacing member (vacuum techniques).
• the bodies may be pressed together and against the spacing member by external forces.
• first and second bodies may be separated slightly from their intended mutual position and maintained in this separated position, and after introduction of the binder the forces causing the separation may be released so that gravitational forces may apply an overpressure to the solidifying binder and return the bodies to their intended mutual position.
• separation of the first and second bodies may performed mechanically by applying external pulling forces, by means of wedges being inserted between the bodies etc.
• An ove ⁇ ressure my also be applied to the solidifying binder by heating or cooling at least part of one of said first and second bodies temporarily while the binder is solidifying.
• pressure may be applied to the solidifying binder between the first and second bodies by pressurising components or devices arranged within or adjacent to the binder.
• Such components may comprise substances changing phase, such as from solid or liquid phase to gas phase.
• mechanical expandable devices may be included in or positioned in direct or indirect contact with the solidifying binder.
• the binding material is any substance capable of binding together the first and second bodies by contact with their opposed first and second surfaces. Strong glues and adhesives have been extensively researched an used in the building, automobile and aircraft industries. As a result, a wide range of binders is available from which to select one suitable for any given application of the present invention.
• the binder may therefore comprise any conventional curable binder or glue, including organic polymer based adhesives such as 2-component epoxys, polurethanes, acrylates/acrylamides, and also fuseable metals or metal alloys, brazing and soldering metals.
• the binder may contain reinforcing bodies such as fibers if desired.
• FIG. 1 is a cross-sectional view of a conventional drawing tool comprising a pair of co-operating tool parts
• Fig. 2 is a cross-sectional view illustrating how a drawing tool part can be made by the method according to the invention
• Fig. 3 is a cross-sectional view showing adjacent structures of different materials, which could be interconnected by a strong bond by the method according to the invention
• Figs 4 and 5 are end views of structures made by the method according to the invention.
• Fig. 6 is a fragmentary sectional view of a reinforced building structure made in accordance with the present invention
• Figs. 7-10 diagrammatically illustrate various embodiments of the spacing member
• Fig. 11 is a fragmentary sectional view illustrating how a liquid binder may be introduced into the space defined between the first and second bodies
• Fig. 12 is a fragmentary sectional view of a cast or moulded body reinforced by metal reinforcing elements in accordance with the method according to the invention
• Fig. 13 is a diagrammatic sectional view of mould parts used for making tiles or similar articles from a cement based material
• Fig. 14 is an axial sectional view illustrating casting of a test sample
• Fig. 15 is a sectional view corresponding to that shown in Fig. 14 and illustrating production of a slightly different test sample.
• Fig. 1 shows a pressing tool comprising upper and lower tool parts 10 and 11, respectively.
• Each tool part comprises a thin metal layer 12, such as a layer of nickel, e.g., of a thickness of 2-4 mm, which is fastened to and backed up by a body 13 of cast DSP material, such as that marketed under the trade mark DENSIT® by Densit A S, Aalborg, Denmark.
• the opposite surfaces of the metal layers are complementary shaped, and the pressing tool may be used for pressing a sheet metal blank 14 into a desired shape.
• the pressing tool may be used for making sheet metal spare parts, such as mudguards or the like, for cars.
• each of the tool parts 10 and 11 are made as follows:
• the metal layer 12 is deposited by a galvanic process on a surface of a sample of the item to be produced.
• the body 13 is made by casting fibre reinforced DENSIT® against the exposed surface of the deposited metal layer 12.
• the body 13 and the metal layer 12 are cleaned and subsequently a layer of binder is applied to the body 13, and the metal layer 12 is repositioned on and fastened to the body 12 by means of the binder.
• Fig. 2 illustrates how a tool part 10 for a pressing tool as shown in Fig. 1 may be made by using the method according to the invention.
• the metal layer 12, such as a layer of nickel, is deposited by a galvanic process to a surface 15 of a model 16, which may be a sample of the item to be produced by the pressing tool.
• a thin spacing member 17 is arranged in close contact with the outer surface of the metal layer 12.
• the spacing member 17 may, for example, be made from a deformable, porous material, and as shown in Fig. 2 the spacing member 17 may contain reinforcing or anchoring members 18 extending transversely outwardly from the sheet-like spacing member.
• the body 13 of DSP material is now cast against the exposed outer surface of the spacing member 17, whereby the protruding end parts of the anchoring members 18 are embedded in the cast body 13.
• a binder for example in the form of a liquid monomer, is introduced into the cavities or pores of the spacing member such that the binder is brought into intimate contact with the adjacent opposite surfaces of the metal layer 12 and the cast body 13, respectively.
• the binder is thereafter hardened or solidified, for example by thermally activated polymerisation of the liquid monomer.
• one or more passages 19 connecting the cavities or pores of the spacing member 17 with the surrounding atmosphere may be formed therein. Sush passage or passages may be used for introducing the liquid binder into the spacing member 17.
• the spacing member 17 may alternatively be made from a solid material which may be removed from the space between the metal layer 12 and the body 13 when the latter has been cast and has solidified.
• the material of the spacing member may, for example, be partly or totally removed after having been melted or evaporated and the removed material is replaced by a binder.
• the spacing member 17 may be made from a solid binder, such as a thermoplastic material, which may be melted and thereby activated.
• the porous spacing member 17 may at least partly be made from a binder component which is activated when a further gaseous or liquid binder component is introduced into the pores or cavities of the spacing member.
• Fig. 3 illustrates more generally how a first structure 20 of one material, such as metal, may be strongly connected to a second structure 21 of another material, such as concrete or DSP material, which has been cast against the first structure.
• a relatively thin spacing member 17, which may be of any of the types described above, is arranged on and formed complementary to an outer surface of the first, prefabricated structure 20. Thereafter, the second structure 21 is cast against the exposed outer surface of the spacing member 17.
• a liquid or gaseous binder is introduced into the spacing member 17 and/or a binder component in the spacing member is activated in any other manner as previously described.
• a binder supply tube 22 extending between the spacing member 17 and an outer accessible surface part of the second structure 21 may be embedded in the second structure and may be used for introducing a binder component into the pores or cavities of the spacing member 17.
• Figs. 4 and 5 show structures each comprising a central body 23 and a surrounding outer body 24.
• the inner body has a circular cross-section while in Fig. 5 it is provided with radially extending fins 25.
• the central body 23 may be made from plastic material, metal, metal alloy or any other solidified material.
• a spacing member or layer 17 which may be of any of the types mentioned above, is applied to the outer surface of the central body 23. Thereafter the outer body 24 may be moulded or cast in situ around and against the spacing member 17.
• the outer member 24 is made from a material different from the material of the central member 23.
• the outer member may be moulded or cast from concrete, DSP material, plastic material, metal or any other material which may be brought into a plastic or liquid state and be caused to solidify after moulding or casting.
• a binder or a component thereof is introduced into the space defined between the central and outer bodies in any of the manners described above.
• the spacing member 17 is preferably compressible so as to allow a possible contraction of the outer body 24 during solidification.
• the structures shown in Figs. 4 and 5 could be made starting with the outer body 24.
• the spacing member could then be applied to the inner surface of the cavity defined therein.
• the central body 23 is made by moulding or casting a mouldable material in the cavity against the spacing member 17. In this case a contraction of the central body during solidification may cause a corresponding radial expansion of the spacing member 17.
• Fig. 6 is a fragmentary sectional view of a building structure made from a basic material 26 of a type which may be moulded or cast, such as concrete or DSP material.
• the basic material may possibly contain reinforcing fibres of any type conventionally used in connection with concrete or DSP materials.
• the building structure further comprises reinforcing elements 27 forming part of a reinforcing structure.
• the reinforcing elements are preferably made from steel or another metal or metal alloy. In the embodiment shown the reinforcing elements are in the form of rods. Alternatively, they may be in the form of strands or wires. Such strands or wires could be made not only from metal, but also from fibres of carbon, plastic, or the like.
• the characteristics of the basic material 26 and the material of the reinforcing elements 27 may be such that a strong durable bond between the basic material and the reinforcing elements can not be obtained when the basic material 26 is brought in direct contact with the reinforcing elements 27 when cast.
• the structure illustrated in Fig. 6 is made as follows: A spacing member or layer 17 of any of the types previously described is applied to the outer surface of each reinforcing element 27 and a reinforcing structure is made by such elements. Thereafter, the basic material 26 is cast or moulded around the reinforcing structure with the spacing layers 17 so as to embed the reinforcing structure in the poured basic material 26.
• the basic material is now allowed to solidify, and thereafter a binder is introduced into the space defined by the spacing layer 17 and/or a binder component present in the spacing layer is activated as described in the present specification.
• the binder may be chosen such that a strong, force transmitting bond is obtained between the basic material 26 and the reinforcing elements 27.
• the binder may be sufficiently elastic to compensate for differences in thermal expansion, etc. of the basic material 26 and the material of the reinforcing elements 27.
• the spacing member or spacing layer 17 may comprise anchoring members 18 of metal or another solid material as shown in Fig. 2 whereby also a mechanical interconnection of the adjacent bodies may be obtained.
• the spacing member may be porous and/or hollow and be adapted to receive a binder or a component thereof in its pores or cavities and/or it may be adapted to be removed totally or partly before the binder or binder component is introduced.
• the spacing member may contain one or more binder components for reacting with the binder component or components being introduced. Another possibility is that the binder is fully contained in or forms the spacing member 17.
• Figs. 7-10 illustrate first and second bodies 28 and 29, respectively, one of which has been cast or moulded against an intermediate spacing member or layer 17 in accordance with the teachings of the present invention.
• the spacing layer 17 contains all the components of the binder by means of which the bodies 28 and 29 are to be interconnected.
• the spacing member 17 is a single layer of homogeneous binder material which may be activated, for example by heating and melting, when one of the bodies 28 and 29 has been cast against the solid layer 17 and has solidified.
• Fig. 8 differs from Fig. 7 by the fact that one end of anchoring members 30 is embedded in the spacing layer 17 while the other end of the anchoring members extends transversely therefrom. When the second body 29 is cast against the spacing layer 17 covering the adjacent surface of the first body 28 the protruding ends of the anchoring members are embedded in the second body as illustrated.
• Figs. 9 and 10 show structures corresponding to the structure shown in Fig. 7 apart from the fact that in Figs. 9 and 10 the spacing layer 17 is divided into two and three sub layers, respectively. Each of these sub layers may contain a binder component. When the spacing layer 17 is activated and melted the various components are intermixed and may react with each other.
• Fig. 11 is a fragmentary sectional view corresponding to those shown in Figs. 7-10.
• inlet passages 31 and 32 are formed in the body 28 and the inner end of the passage 32 forms an inlet manifold 33.
• Each of these passages interconnects the space defined between the bodies 28 and 29 by the spacing member 17 with external binder pressurising means, not shown.
• the spacing member 17 may include a binder or the binder may be introduced in a porous or hollow spacing member as explained above.
• binder when the binder has been activated and or introduced into the space between the bodies 28 and 29 binder under pressure or another pressurised medium, such as liquid or gas, may be applied to the passages 31 and 32 while the binder is solidifying as indicated by arrows 34 in Fig. 11.
• another pressurised medium such as liquid or gas
• the structure shown in Fig. 12 corresponds to that shown in Fig. 6 comprising a moulded or cast basic material 26 and a rod-shaped reinforcing element 27, which is surrounded by the spacing member 17.
• the reinforcing element 27 and the surrounding spacing member 17 is encircled by a spiral reinforcing member 35 which is embedded in the basic material 26.
• the binder, which is included in or injected into the spacing member 17, may be pressurised while solidifying as explained above.
• the spiral member 35 may then function as a back-up member for taking up forces provided thereby, so as to counteract formation of cracks or disintegration of the basic material 26 around the spacing member 17.
• FIG. 13 illustrates mould parts made in accordance with the method of the present invention and for use in forming tiles.
• a mould part 36 comprises a body member or back up member 37 cast from a DSP material and a metal layer 38 connected to the upper surface of the back up member 37.
• the metal layer may be drawn from sheet metal, such as stainless steel, or may be made by galvanic or electrolytic precipitation as described above.
• the mould part is to be used for forming a tile or a similar article it is placed on top of a supporting body 39 having an upper surface, which is complementary to the lower surface of the mould part 36, and a plane bottom surface.
• the assembly formed by the supporting body 39 and the mould part 36 may then be arranged on a table 40 of a compacting apparatus, not shown.
• the supporting body 39 may have been made in the same manner as the mould part 36.
• it may comprise an upper metal layer 41 , which is bonded to a base member 42 made from for example cast DSP material.
• a metered amount of concrete or another cement based material may be dispensed onto the upper surface of the mould part 36 and an upper mould part, not shown, may be moved into engagement with the lower mould part 36 so as to define a mould cavity in which the concrete is compressed or compacted and possibly exposed to vibrations.
• the mould When the concrete or cement based material has been compacted so as to form a "green" tile 43 or another article the mould may be opened and the mould part 36 with the green tile may be removed from the compacting apparatus and passed to a curing area. Thereafter, a new mould part may be arranged on top of the supporting body 39 on the table 40 of the compacting apparatus.
• a composite body was made in accordance with the present invention in the following manner.
• a plane, circular nickel shell 50 with a diameter of 100 mm and a thickness of 2 mm was electro formed on a plane mandrel surface.
• the nickel shell 50 thus formed was placed on the bottom plate 51 of a mould as shown in Fig. 14.
• a layer of a steel wire mesh 52 with a mesh size of 2 mm and a wire diameter of 0.5 mm was arranged on the upper surface of the bottom 51 and a textile filter 53 of non-woven polyethylene fibres and with a thickness of 0.2 mm was placed on top of the wire mesh 52.
• a mortar was made from Densit ToolCast marketed by Densit -A/S, Aalborg, Denmark (Densit ToolCast is a Portland cement-based DSP material to which, during mixing, is added 4.5 % w/w steel fibres of diameter 0.4 mm, length 12.5 mm, tensile strength 1200 MPa).
• the mortar was poured into the mould and a steel rod 57 was arranged axially therein so that one end portion thereof dipped into the mortar while the other end portion of the rod extended upwardly from the mortar.
• the textile filter 53 prevented the mortar from penetrating into the wire mesh 52.
• the mould with the mortar was vibrated and cured/hardened so as to form a solid body 58.
• a resin based epoxy adhesive marketed under the trade name Araldite® 2019 by Ciba Speciality Chemicals Pic was injected into the wire mesh 52 and into the textile filter 53 through central openings 63, which were formed in the bottom plate 51 and in the nickel shell 50, by means of a manually operated mixing pump adapted to mix the two components of the adhesive.
• Araldite® 2019 is a relatively low viscosity (3 Pas) adhesive described in greater detail in a brochure "Industrial Range Araldite, Publication No. A418a-GB 3000/08/992 W&B, published by Ciba Speciality Chemicals PLC 1998.
• a composite body or test sample similar to that described in example 1 was made in a mould as illustrated in Fig. 15.
• the nickel shell 50 and the wire mesh 52 were the same as described in example 1. This time, however, no textile filter was used.
• the nickel shell 50 was placed on top of the mould bottom plate 51, and a 0.5 mm thick layer of adhesive was applied directly to the upper surface of the shell 50.
• the adhesive was of the type marketed under the trade name DanikumLim 6233 by Frede Andersens Fabriker A/S, Lille Skensved, Denmark, a polystyrene acrylate aqueous dispersion adhesive suitable for "wet in wet" application.
• the wire mesh 52 was placed on top of the adhesive layer and pressed into contact with the nickel shell 50 by means of the screws 55 as described above in example 1.
• the ceramic body 58 was cast on top of the wire mesh 52 in the same manner as described in example 1.

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• Organic Chemistry (AREA)
• Laminated Bodies (AREA)

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  • 2000-05-10 AU AU46008/00A patent/AU4600800A/en not_active Abandoned
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  • 2000-05-10 EP EP00927618A patent/EP1189736A1/de not_active Withdrawn

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