HU0303320A2 - A layered sheet material such sheet materials and methods for preparing - Google Patents

A layered sheet material such sheet materials and methods for preparing Download PDF

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Publication number
HU0303320A2
HU0303320A2 HU0303320A HU0303320A HU0303320A2 HU 0303320 A2 HU0303320 A2 HU 0303320A2 HU 0303320 A HU0303320 A HU 0303320A HU 0303320 A HU0303320 A HU 0303320A HU 0303320 A2 HU0303320 A2 HU 0303320A2
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HU
Hungary
Prior art keywords
characterized
layer
sheet material
functional layer
water
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Application number
HU0303320A
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Hungarian (hu)
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HU0303320A3 (en
Inventor
John Sydney Cottier
Robert Lyons
Basil Naji
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James Hardie Research Pty Limited
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Publication date
Family has litigation
Priority to AUPR3478A priority Critical patent/AUPR347801A0/en
Priority to AUPR3476A priority patent/AUPR347601A0/en
Priority to AUPR3475A priority patent/AUPR347501A0/en
Priority to AUPR3477A priority patent/AUPR347701A0/en
Priority to AUPR3474A priority patent/AUPR347401A0/en
Application filed by James Hardie Research Pty Limited filed Critical James Hardie Research Pty Limited
Priority to PCT/AU2002/000241 priority patent/WO2002070247A1/en
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=27507501&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=HU0303320(A2) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Publication of HU0303320A2 publication Critical patent/HU0303320A2/en
Publication of HU0303320A3 publication Critical patent/HU0303320A3/en

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS, SLAG, OR 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
    • B28B1/522Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement for producing multi-layered articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS, SLAG, OR MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/40Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material
    • B28B7/46Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material for humidifying or dehumidifying
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04Waste materials; Refuse
    • C04B18/06Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
    • C04B18/08Flue dust, i.e. fly ash
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02Compositions 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 hydraulic cements other than calcium sulfates
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04Building 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
    • E04C2/06Building 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 reinforced
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/02Coverings or linings, e.g. for walls or ceilings of plastic materials hardening after applying, e.g. plaster
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/12Flooring or floor layers made of masses in situ, e.g. seamless magnesite floors, terrazzo gypsum floors
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482Coating or impregnation materials
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/90Reuse, recycling or recovery technologies cross-cutting to different types of waste
    • Y02W30/91Use of waste materials as fillers for mortars or concrete
    • Y02W30/92Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S106/00Compositions: coating or plastic
    • Y10S106/01Fly ash
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/249921Web or sheet containing structurally defined element or component
    • Y10T428/249924Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/249932Fiber embedded in a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/249921Web or sheet containing structurally defined element or component
    • Y10T428/249953Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249967Inorganic matrix in void-containing component
    • Y10T428/249968Of hydraulic-setting material
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/249921Web or sheet containing structurally defined element or component
    • Y10T428/249953Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249971Preformed hollow element-containing
    • Y10T428/249972Resin or rubber element
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/249921Web or sheet containing structurally defined element or component
    • Y10T428/249953Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249986Void-containing component contains also a solid fiber or solid particle
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/25Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/26Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/263Coating layer not in excess of 5 mils thick or equivalent
    • Y10T428/264Up to 3 mils
    • Y10T428/2651 mil or less
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/31652Of asbestos
    • Y10T428/31667Next to addition polymer from unsaturated monomers, or aldehyde or ketone condensation product
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/10Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]

Abstract

The layered sheet material, especially for construction use, in particular skeletal sheet material, comprises at least one additional functional layer produced from the aqueous material mixture of a base layer and a hydraulic binder and water content reducing additive (s) applied thereto. The essence is that the starting material mixture (s) containing the sufficient amount of water-reducing additive (s) for their dehydration through the azalapril and optionally further functional layer (s) is (are) produced by the functional layer (s). According to a method for the production of such layered building materials having a plurality of properties having a targeting characteristic according to the intended use, a base layer is pre-fabricated and a water mixture comprising a hydraulic binder and at least one water-reducing additive is prepared. The aqueous material mixture is applied to the substrate by applying a functional layer to the substrate, dewatered to remove water: The process steps for preparing, applying and dewatering the aqueous material mixture may be repeated cyclically, while the functional layer (s) is (are) prepared as aqueous material mixtures. the water content reduction additive (s) is applied in an amount sufficient to cause dewatering of the functional layer (s) on the base layer and optionally further functional layer (s). HE

Description

Extract

Layered sheet material and method for producing such sheet materials

The layered sheet material, especially for construction use, in particular skeletal sheet material, consists of at least one additional functional layer produced from an aqueous material mixture of a base layer and a hydraulic binder and water content reducing additive (s) applied thereto. The essence is that the functional layer (s) are (are) produced from a starting material mixture (s) containing water-reducing additive (s) in sufficient amounts to dehydrate them through the base layer and optionally further functional layer (s). . According to a method for the production of such layered construction sheet materials having purposefully adjustable characteristics and properties according to the intended use, a base layer is first formed and an aqueous mixture of at least one water-reducing agent is prepared. When applied to the base layer, the aqueous material mixture creates a functional layer, dewatering or dewatering. Process steps for the preparation, application and dewatering of the aqueous material mixture are optionally cyclically repeated, while the water-reducing additive (s) (s) on the functional layer (s) are (are) added to the aqueous material mixtures prepared as the starting material (s) for each functional layer (s). and used in an amount sufficient to dewater through the optional additional functional layer (s).

4668S

PCT / AU0200241 'CUSTOMIZING DRESS

Ρ0303320

Layered sheet material and method for producing such sheet materials

FIELD OF THE INVENTION The present invention relates to a layered sheet material, in particular for use in construction, in particular a skeleton sheet, comprising at least one additional functional layer from an aqueous material mixture of a base layer and a hydraulic binder and water content reducing additive (s) applied thereto. The invention also relates to a method for producing such sheet materials.

The following description of the prior art is intended to illustrate the invention in an appropriate technical context and to emphasize the importance of the invention. However, unless indicated otherwise, a reference to the prior art in the following description does not mean that it should be considered to be a widely known or general knowledge or knowledge in the art.

Cement-based skeletal concrete, commonly used in the art, and repeatedly used in the art, is FRC, a highly popular and widely used construction material. In collaboration with collaborative partners, we have also developed a number of technological processes for the production of cement-based drywall construction products and for the adaptation of these FRC sheets to the particular use environment and application area.

However, some production difficulties and application constraints of the FRC sheets are known. The FRC boards do not have the proper acoustic, thermal and fire performance in all respects. Their machinability is limited and their density is generally 1300 kg / m 3 approx. 1700 kg / m 3 Compressed, high density range around.

The properties of the skeletal cement material are generally different from materials such as different fibers, fillers, and the like. can be influenced by doping or using different production technologies. The composition of the FRCs is such

THE ·· · ·

However, -2 modifications can often only be made with significant cost benefits if we want to avoid the occurrence of adverse side effects in new formulations. Some targeted modifications to manufacturing processes and equipment can also be developed at a high cost and time consuming. At the same time, known experiments and solutions do not provide true customization of the FRC sheet, which is meant to fit and optimize their characteristics to the requirements of the particular application field. For this, a suitable solution is not suitable if, for example, a small batch of FRC for special use requires a complete production line to be shut down for a longer period in order to make the necessary change.

It is an object of the present invention to at least partially eliminate the disadvantages of prior art prior art solutions or to provide alternative solutions.

The object of the present invention is to obtain and apply a layered sheet material having at least one additional functional layer produced from an aqueous material mixture of a base layer and an additive (s) of hydraulic binder and water content reducing agent applied to it, in accordance with the most common embodiment of the present invention. available. According to the invention, the functional layer (s) are / are produced from a mixture of starting materials containing the water-reducing additive (s) in sufficient amounts to dehydrate them through the base layer and optionally further functional layer (s).

A further object is to provide and employ a process for first preparing a base layer and then preparing an aqueous mixture of a hydraulic binder and at least one water-reducing additive or additive. Applying the aqueous mixture to the base layer, a functional layer is formed, then the functional layer is dewatered or dehydrated. The aqueous material mixture preparation, application, and dewatering steps may optionally be cyclically repeated while the water content reducing additive (s) (s) on the functional layer (s) are (are) added to the aqueous material mixtures prepared as the starting material (s) for each functional layer (s). and further included

Sufficient porosity is used to dewater through the functional layer (s).

The base layer of the sheet materials according to the invention is preferably a skeletal base material such as fiber-skeletal cement. This base layer forms a structural base onto which additional functional layers can be applied.

Functional layers can be applied to both sides of the base layer, but they are preferably applied only to one side of the base layer, which side forms one surface of the construction sheet material during manufacture. In order to produce such sheet materials according to the invention, the method according to the invention can advantageously be carried out on modern Hatschek machine lines for the production of known FRC sheet materials.

According to the method of the invention, layered sheet materials suitable for almost any desired specification or application can be produced. As a first step of the process according to the invention, a simple, water-permeable base layer, such as a conventional sheet-frame construction sheet material, is obtained or produced. One or more functional layers are applied to this base layer, each functional layer being formed according to the desired functionality requirements. For example, if an insulating layer is to be formed, an aqueous material mixture for forming a functional layer, in particular cement paste composition, may be provided with insulating materials such as rubber powder, vermiculite, perlite, gypsum, and the like.

Similarly, waterproof polymers such as silanes, siloxane blends, etc., or puzzolan-containing materials, clay powder, metakaolin, ultrafine flake fly and the like can be used to reduce water permeability.

Lightweight materials suitable for the mixture of materials, such as hollow spheres (hollow spheres), expanded polystyrene, vermiculite, perlite, etc., are suitable for modifying the density of the functional layer. doped.

By suitable modification of the starting material mixture, in particular cement pulp according to the method of the invention, various functional layers can be integrated into a single layered sheet.

In preferred embodiments, the sheet materials of the present invention also comprise at least one reinforcing layer between each functional layer. The stiffening layer may comprise a fabric or web of fibrous material for enhancing the strength and durability of the laminated sheet material.

-4 In some cases, the stiffening layer may comprise a thin, skeletal, cement-containing layer similar to the base material. This, like sandwich technology, ensures more efficient use of such skeletal layers. One skilled in the art can appreciate the importance of having a layered sheet material having areas such as the core, which require a smaller beam frame. In the panel elements of the present invention, the core area may be formed as a low-fiber reinforcement as a functional layer as mentioned above. In order to achieve high tensile strength, large areas of fibrous reinforcement, such as surfaces or shell areas, can be formed as fibrous cement-containing concrete coating layers. The resulting skeletal layers function as a sandwich shell, while the water-depleted cement pulp functional layer serves as a less fiber-reinforced or stiffened sandwich core.

As a result, the laminated sheet materials of the present invention have significant advantages over fiber-skeletal monolithic materials. First of all, thanks to the co-operative effect mentioned above, fibers can be placed in areas where they are most needed. In this way, the volume of the sheet material stiffened by a strand can be significantly reduced.

Secondly, this reduced fiber volume improves the fire resistance and thermal insulation properties of the sheet material. The production of non-combustible conventional sheet materials has so far been problematic due to the high cost of non-combustible, refractory fibers and the special procedures required for their production.

Another very important advantage of the sheet materials according to the invention is that a given functionality can be concentrated on a particular layer. For high-monolithic layers, especially for skeletal cement construction products, the functional or structural modifications of the product may dilute or disappear or divide unevenly into the product. Further, adverse side reactions may occur during the production of such monolithic products, which may result in the loss of the desired structural or functional properties. In the case of laminated sheet materials according to the invention, however, the specific functional or structural properties can be concentrated in a single or discrete functional layer (s), which ensures that the layered sheet material is guaranteed with the desired property or characteristics.

-5The functional layer (i) of the sheet material according to the invention also includes additives and / or fillers that improve the density, material use or production cost efficiency, water-permeability, and / or aesthetic properties of the sheet material which affect the acoustic, thermal or fire resistance properties of the sheet material. contain (s).

On the layered layer, an upper surface coating layer can also be formed by applying a fibrous cement-based layer, a material similar to or equivalent to the functional layer, or other product. In a particularly preferred embodiment, the top or topcoat may be a layer of aesthetic appearance, such as a layer comprising ultrafine particles, or a layer of sandable material that can be sanded smoothly to form a ready-to-use or easy-to-paint surface.

Unless the context explicitly requires otherwise, the terms used in the specification and claims and the like expressions are non-exclusive, i.e. contain, but are not limited to, may include other meanings.

The water-reducing additive is used to maintain the porosity of the aqueous binder containing the hydraulic binder, in particular cement pulp and the product to be coated, to allow the cement pulp to drain through the product to be coated. Preferably, the water content reducing additive is a particulate material such as fly ash, aluminum oxide trihydrate, clay flour, casserole beads (hollow ceramic balls) or the like.

The fly ash is particularly preferred as it allows the cement pulp to drain in a few minutes. Other water-reducing additives such as aluminum oxide trihydrate or clay flour may be used, however, they require longer time to dewater the cement pulp through the product to be coated.

In a preferred embodiment, the cement pulp applied to the article to be coated has a high water content. The water content may conveniently be up to 50% by weight. This is in contrast to previous cement-containing compositions, which usually have a high dry matter content.

By combining the various components of the starting material mixture described above, a self-leveling cement pulp is obtained which is

Í * '· -.

-6 can be applied to the base layer, rapidly dewatering through the base layer, creating a uniform coating.

Normally, after application of the coating, the product obtained can be matured, matured or hydrothermally matured, i.e. autoclaved and, if necessary, sanded to provide a smooth surface.

The base layer to which the functional layers can be applied can be any size, provided that the cement pulp can drain through the base layer. Known cement-containing and gypsum-based construction sheet materials are jcement and gypsum boards) with excellent oylan base layer materials that can be applied to the coating.

The thickness of the functional layers is preferably between 0.1 and 10 mm, preferably between 0.5 and 5 mm and most preferably between 1 and 3 mm.

After the desired, if desired or necessary grinding, the thickness of the coating layer may be between 0.05 and 5 mm, preferably between 1 and 2 mm, and most preferably between 0.5 and 1 mm. The laminated sheet material of the present invention has a roughly the same workability as the monolith (single layer) sheet material. It can be bent, cut, drilled and nailed to a frame without cracking or peeling the surface.

Our experience is that there is a very good inter-layer bonding and compatibility between the water-depleted cement pulp layer and the base layer, which results in excellent working, compatibility and resistance to peeling.

The term "hydraulic binder" as used herein and in the claims refers to a powdered solid, dry material which, when mixed with water, forms plastic mixtures which can bind and harden. Examples of such hydraulic binders are various cements. White, gray or pigmented cement and hydraulic lime are also included in the definition.

The term "cement" means water-binding and sub-cement, such as Portland cement, mixed cements, such as Portland cement mixed with fly ash, blast furnace slag, puzzolan and the like, and mixtures thereof, masonry cement, oil slate cement, natural cement, alumina cement, expansive cement and the like, or mixtures thereof.

In the starting material mixtures used for each layer of sheet material according to the invention, the proportion of the hydraulic binder is the total dry matter.

Preferably between 10 and 50% by weight, more preferably between 15 and 40% by weight, most preferably between 20 and 30% by weight.

The use of fly ash for sheet material according to the invention has several advantages because it serves, inter alia, and especially as a reducing agent for the water content of the pulp, as stated above.

The term "fly ash" refers to a solid powder having a chemical composition similar to, or equivalent to, a solid formed by the combustion of carbon powder, i.e. 25 to 60% quartz, 10 to 30% by weight AI 2 HE 3 , 5-25% by weight Fe 2 HE 3 , 0-20% CaO and 0-5% MgO.

Another preferred water-content reducing additive may be a coarse frosted fly ash containing particles of greater than 100 μm. Such a coarse fraction of fly ash may contain grate ash or similar products from coal combustion. The advantage of using this coarse fraction instead of the aforementioned fine particle size fly ash is that it is cheap. It will be appreciated by those skilled in the art that, of course, some modification of the composition of the cement pulp may be necessary to obtain suitable coating and suitable dewatering properties when using such coarse fractions as a water-reducing additive.

The fly ash particles are typically spherical with diameters between 1 µm and 100 µm. In a preferred embodiment, the fly ash comprises two components. The maximum size of a first larger particle size of the fly ash is preferably 100 µm. This size range of fly ash in cement cement, in addition to improving the dewatering characteristics of cement pulp, also acts as a moderately reactive puzzolan.

The second, smaller size fly ash with a maximum particle size of 10 μm, in addition to reducing the drainage characteristics, is a highly reactive puzzola. This smaller particle size fly ash also improves the surface quality of the surface finish.

In a preferred embodiment, the first fly ash fraction is between 10 and 60% by weight of the dry solids, more preferably between 20 and 50% by weight and most preferably between 30 and 40% by weight of the mixture.

+ · · · · · · · · · · · · · ·

Preferably, the second fly ash component is present in the material mixture between 5 and 30% by weight of the dry solids, more preferably between 10 and 25% by weight and most preferably between 15 and 20% by weight.

Optionally, the functional layers may also contain other additives, such as fillers. These fillers can also be used to improve the dewatering properties of cement pulp. For example, cobwebs (hollow ceramic microspheres), diatomite, wollastone, ground rice shell, ground perlite, etc. especially suitable for this purpose.

These and other fillers may also provide additional benefits, for example, calcium carbonates or aluminum oxide hydrates improve the abrasion or elasticity of the coating applied. Clay flour enhances the hardness of the polished surface of the coating layer, and the sound insulation / heat insulation properties of the layer can be improved by the use of rubber particles, vermiculite, perlite, shredded or expanded polystyrene or gypsum.

In the aqueous material mixture, the fillers are preferably present in an amount of between 5 and 30% by weight of the dry matter content, more preferably between 10 and 25% by weight, and most preferably between 25 and 20% by weight.

Functional layers may also contain other organic additives. Known cement fluxes can be used to modify the viscosity of, for example, cement pulp. Suitable cement fluxes include sulfonate formaldehyde condensates, naphthalene sulfonate formaldehyde condensates, naphthalene sulfonates, calcium lignosulfonates, sodium lignosulfonates, sucrose, sodium gluconate, sulfonic acids, carbohydrates, aminocarbide acids, polyhydroxy carboxylic acids, sulfonated melomine, and the like;

The proportion of cement fluxing agent naturally depends on the fluidizing ability of the particular fluxing agent. It is generally recommended to use the flocculant in an amount of between 0.3 and 3% by weight of the dry matter, preferably between 0.5 and 3% by weight.

Particularly good cement flocculant is Melament F-10 type designation, which is a melamine-formaldehyde sodium bisulfate polymer dispersant which is marketed in the form of fine white powder by SKWTrostburg. Another good fluxing agent is Neosyn, a condensed sodium salt of sulphonated naphthalene and available from Hodgson Chemicals.

+ • · β ·· ···· • ·. ···. : ··

..... ··· .-. · ...

A further preferred component used in the coating is a bipolymer that increases the viscosity, segregation resistance, and self-deflection characteristics of the cement paste. Particularly good bipolymers are xanathan gum and / or welan rubber, such as KELCO-CRETE, K1C 376, manufactured by Monsanto.

To improve the adhesion, flexibility, stability and impermeability of the functional layers, latex may also be advantageously added to the wet starting material mixture. The latex also improves the flexibility of the sheet material of the finished layered structure.

Suitable latex is preferably selected from the group consisting of acrylatex, styrene latex, butadiene latex, or a mixture thereof, and is preferably present in the mixture at a level of from 0.5% to 20% by weight of the solids component cement, preferably from 1% to 15% by weight on a polymeric solid base. and most preferably in an amount of 10% by weight.

As additional additives or as substitutes for latex emulsions, vinyl polymers can also be used in the mixture. Vinyl polymers or other polymeric materials suitable for use with them enhance the adhesion, elasticity and flexural strength and wear resistance of the functional layer.

Preferred vinyl polymers include polyvinyl acetate or a copolymer of vinyl acetate with another monomer such as ethylene. A particularly suitable vinyl acetate resin is the VINNAPAS LL5044 thermoplastic resin powder, which is a vinyl acetate ethylene copolymer product available from Wacker. This powder of vinyl polymer may conveniently be used in an amount similar to the latex emulsion.

Conventional and other additives, such as mineral oxides, hydroxides and clays, metal oxides and hydroxides, flame retardants, such as magnesite, thickeners, clay flour or amorphous clay, water-sealing additives, water-reducing additives, binding modifiers, curing agents, dispersing agents, foaming agents or flocculants, waterproofing agents, are known in the art. and density modifiers may also be used in the aqueous material mixture (s) used as the starting material (s) for the base layer or (some) functional layer (s) of the sheet materials of the present invention.

·· ·

In the case of -10E, one particular advantage of the laminated sheet materials according to the invention is that the product to be coated can be treated with additives used in the functional layer. This may be due to the fact that the cement pulp is dewatered through the product to be coated, so that additives that may be added to the material mixture, in particular cement pulp, may optionally be added to the substrate. For example, a water barrier such as silane may be added to the material mixture to a greater extent than the requirements of the functional layer. During the dewatering, the silane penetrates and penetrates through the base layer, providing it with silane treatment to increase water resistance. An important additional advantage of the method according to the invention is that the base layer can be further treated in the base layer by means of or through the applied layer, and it can also create or further improve or enhance a desired or desired property.

The essence of the invention will be described in more detail below with reference to exemplary embodiments. The sheet materials of the examples were prepared by the following process steps.

Step 1: The first step in the production process is to prepare the liquefied material mixture, especially cement pulp according to the prescribed formulation. For the production of cement pulp, a hydraulic binder, fly ash and, if desired, other components were mixed with water. The solids content of the cement pulp is preferably between 50 and 90%, more preferably between 55 and 80%, most preferably between 60 and 70%.

Step 2: In the next step of the process, the flocculated material, in particular cement pulp, is applied, dispersed and dewatered or dehydrated. The cement paste is deposited on the base layer by any conventional means known in the art, such as dough rollers, knives, nozzle feeders, and the like. we took it. The composition and consistency of the material mixture, in particular cement pulp, was selected for self-leveling and a uniform coating on the substrate. The coating product, which is the base layer to be coated, is always porous to some extent, thanks to this property, the applied layer of water is dewatered and a uniform layer of cement is formed therefrom. The time required for dewatering can vary greatly, but normally ranges from 10 to 90 seconds, depending on the porosity, the water content and the thickness and viscosity of the applied pulp. If necessary, vacuum can be used to reduce pulp ··· · • · ·

-11 water drainage time. This is particularly useful if the coating process is to be adapted to the manufacturing speed of a manufacturing device for the production of a construction product, in particular sheet material. For the conventional rate of sheet material production on known Hatschek production lines, the optimum time for dewatering is, for example, between 40 and 45 seconds.

Step 3: The third characteristic step of the process is the maturation of the crude product, the preferred preference being that the raw preform consisting of the base layer product and at least one coating applied to it is first preheated for a relatively short period of time, e.g. or maturation at room temperature, steam-matured at 40-90 ° C, or in an autoclave with steam at 120 ° C to 200 ° C.

At any of these maturation technologies, a maturation period of from 6 to 72 hours, preferably up to 48 hours, is sufficient. It is well known in the art that the length of time selected for maturation depends on the material composition, the manufacturing process employed and the shape of the product.

In the following examples, some specific examples are provided for formulations or material compositions useful for the preparation of the particular coating or intermediate layers of the laminated sheet materials according to the invention.

Example 1

To produce a sandable topcoat for long-lasting building facades, a low viscosity, low-water cement paste with a drainage time of 3.4 m in a 50 ml funnel was prepared and laid out in one particular example! In this case, the Hardiform ™ branded cellulose fiber reinforced cement based, 12 mm thick wet sheet base layer used as a base layer by James Hardie Industries. Without the use of vacuum, the cement paste dewatered in 90 seconds and created a 1.25 mm thick coating. The coated sheet was aged in an autoclave for 8 hours at 180 ° C and a pressure of 0.80 MPa. The layer of matured sheet material is industrial • · • ·· ·

-12-sanding machine was sanded smoothly with a particle size of 100, until a thickness of 0.60 mm was achieved.

All the ingredients

Ingredients for the cement pulp mixture % by weight of solids (S) Weight (g) Cement-containing aqueous material mixture inorganic constituents of cement paste: Portland cement 30 12000 Quartz Flour (400 G Fine) 10 4000 Flyper (larger fraction size) 40 16000 Flywheel (smaller fraction size) 20 8000 All 100 40000 Water (W) 14000 Water / solid (W / S ratio) 0.35 Solid content (W / W + S ratio) 0.74 Added organic additives Welan Rubber (Kelcocrete) 0.0075 3.0 Naphthalene-formaldehyde flux (Neosyn) 0.25 100.0 Rhoplex MC 1934 acrylic emulsion 1.0 400.0

Example 2

For anti-slip floor coverings, abrasion-resistant electrostatic dissipative floor coverings and acoustically insulating slabs, a low-viscosity aqueous cement pulp with a reduced water-retention time of 50 ml in a 50 ml funnel was used to produce the topsheet. The pulp was laid out in one particular example! In this case, the Hardiform ™ branded cellulose fiber reinforced cement based, 12 mm thick wet sheet base layer used as a base layer by James Hardie Industries. Without the use of a vacuum, the pulp dewatered in 60 seconds and resulted in a 1.25 mm thick coating. The coated sheet is heated to 180 ° C for 8 hours

It was aged in an autoclave at -13 and at a pressure of 0.80 MPa. The layer of matured sheet material was sanded smoothly with a 100 grit sandpaper with an industrial abrasive machine until a thickness of 0.60 mm was achieved.

All the ingredients

Ingredients for the cement pulp mixture % by weight of solids (S) Weight (g) Cement-containing aqueous material mixture inorganic constituents of cement paste: Portland cement 30 12000 Filtered through a -30 mesh sieve recycled rubber crumb 10 4000 Flyper (larger fraction size) 40 16000 Flywheel (smaller fraction size) 20 8000 All 100 40000 Water (W) 13000 Water / solid (W / S ratio) 0.325 Solid content content (W / W + S) 0.755 Added organic additives Welan Rubber (Kelcocrete) 0.0075 3.0 Naphthalene-formaldehyde flux (Neosyn) 0.25 100.0 Rhoplex MC 1934 acrylic emulsion 1.0 400.0

Example 3

A cementitious skeleton concrete substrate or coating on a low viscosity, low-viscosity wet cement paste having a depletion time of about 50 ml in a 50 ml funnel was used to produce a flexible and abrasive thin top coat. The pulp was applied to one particular example! case Hardiform ™ branded by James Hardie Industries, a cellulose fiber reinforced cement based 4.5 mm thick wet sheet. Without the use of a vacuum, the water has dehydrated in 120 seconds and is 1.25 mm thick

-14covered a coating. The coated sheet was prewashed for 48 hours and then aged in an autoclave for 8 hours at 180 ° C and 0.80 MPa. The layer of matured sheet material was sanded smoothly with a 100 grit sandpaper with an industrial abrasive machine until a thickness of 0.60 mm was achieved.

Ingredients for the cement pulp mixture

Inorganic components of cementitious aqueous cement mixture (cement pulp): Portland cement

Calcium carbonate with a fine particle size of 40 μm and a fine particle size of 40 μm, with an average particle size of 80 μm. Percussion (larger fraction size).

Water (W)

Water / solids (W / S ratio) Solids content (W / W + S ratio) Added organic additives Welan rubber (Kelcocrete)

Naphthalene-formaldehyde flux (Neosyn)

Styrene-acrylic latex emulsion with 56% solids content

Example 4

The percentage by weight (g) of the ingredients for total solids (S)

20 8000 10 4000 5 2000 45 18000 20 8000 100 40000 12000 0.30 0.77 0075 3.0 0.25 100.0 5 2000

To produce a thin and thin layer of thin concrete with reduced skeleton, reduced cement content and water requirement, a low-viscosity aqueous cement paste with a cessation time of 4.5 m in a 50 ml funnel was prepared. The pulp was applied as a base layer by James Hardie Industries

-15 Hardiform ™ branded cellulose fiber reinforced cement based 4.5 mm thick wet wet sheet. Without the use of a vacuum, the pulp dewatered in 90 seconds and resulted in a 1.25 mm thick coating. The coated sheet was aged in an autoclave for 8 hours at 180 ° C and a pressure of 0.80 MPa. The layer of matured sheet material was sanded smoothly with a 100 grit sandpaper with an industrial abrasive machine until a thickness of 0.60 mm was achieved.

All the ingredients

Percentage by weight (g) of the cement pulp mixture for solids (S)

Inorganic components of cementitious aqueous mixture (cement pulp):

Portland cement 10 4000 10, 40 μg average particle size calcium carbonate 20 8000 80 μm average particle size aluminum oxide trihydrate 5 2000 Flyper (larger fraction size) 40 18000 Flywheel (smaller fraction size) 25 10000 All 100 40000 Water (W) 16000 Water / solid (W / S ratio) 0.40 Solid content (WA / V + S ratio) 0.715 Added organic additives: Welan Rubber (Kelcocrete) 0.0075 3.0 Naphthalene-formaldehyde flux (Neosyn) 0.25 100.0 powdered vinyl acetate ethylene copolymer (Winnap LL5004) 1.625 650

The products described in the above examples are laminated sheet materials of the present invention having similar machinability to sheet material with a monolith or a single topsheet. According to the invention

-16 sheet materials can be bent, cut, drilled, or pegged at least to a limited extent without surface cracks or punctures.

The finished surface already finished in the manufacturing plant remains smooth, crack free and low permeability even when used in curved form.

Each sheet material of the example has an excellent interlayer bond between the motherboard and the coating, the results of the experiments carried out show good co-working, compatibility, and resistance to lamination.

For the production of sheet materials according to the invention, a method has been developed by means of which fiber-skinned layers can be functionally combined with water-reduced (cement) pulp layers, optionally with synthetic or natural fibers such as polypropylene, glass, PVA, cellulose fibers and the like. reinforced with fibers. The result of the process according to the invention is a layered concrete frame product which combines the strength, water resistance and non-combustibility of the fibrous cement materials with the low density, surface finish and insulation properties of a plasterboard.

According to the applicants, using the techniques described above, functional layers can be applied to the base layer without being detached or inconsistent between the layers, i.e. there is no shrinkage, warping or the like.

It will be appreciated by those skilled in the art that many other embodiments of the layered sheet materials of the present invention not specifically described herein may be implemented. The sheet materials according to the invention, as described in our parallel patent applications of the same priority, can be made very advantageously using various water-reducing mineral additives and application equipment for the production of coatings of various purposes for construction products and other similar coatings.

purpose,

Claims (48)

  1. Claims
    1. Layered sheet material, in particular for use in construction, in particular skeletal sheet material, comprising at least one additional functional layer from a base layer and an aqueous material mixture of a hydraulic binder and water content reducing additive (s) applied thereto, characterized in that said functional layer (s) comprises: (s) from the starting material mixture (s) containing a sufficient amount of water-reducing additive (s) to dehydrate them through the base layer and optionally further functional layer (s).
  2. The sheet material according to claim 1, characterized in that the functional layer (s) each comprises a functional additive suitable for producing the desired characteristics of the respective layer.
  3. Sheet material according to claim 1 or 2, characterized in that the structural material of the base layer is a skeletal material.
  4. 4. Referring to 1-3. Sheet material according to one of Claims 1 to 3, characterized in that the base layer is a skeletal base material comprising a hydraulic binder, in particular cement.
  5. 5. Sheet material according to one of Claims 1 to 3, characterized in that it comprises functional layers applied to both sides of a base layer.
  6. 6. Sheet material according to one of Claims 1 to 3, characterized in that it comprises a functional layer (s) applied to one side of a base layer.
  7. 7. Sheet material according to one of Claims 1 to 3, characterized in that the functional layer (s) (i.e., respectively) is coated with a stiffening layer.
  8. 8. Referring to Figures 1-7. Sheet material according to one of Claims 1 to 4, characterized in that the reinforcing layer comprises a fabric or web of a fibrous material.
  9. 9. Sheet material according to one of Claims 1 to 3, characterized in that the stiffening layer is a skeletal layer made of a mixture of starting materials containing a hydraulic binder, in particular cement.
  10. 10. References 1-9. A sheet material according to any one of claims 1 to 3, characterized in that it comprises at least one functional layer of reinforcing fiber, including an outer layer made of a cementitious starting material mixture and an arrangement thereof.
    ···· ····
    - 1811. Sheet material according to one of Claims 1 to 3, characterized in that the fiber content of the fiber backbone of the functional layer (s) is smaller than the fiber content (s) of the layer (s) of the layer (s) of starting material mixture containing the hydraulic binder, in particular cement.
  11. 12. A sheet material according to any one of claims 1 to 3, characterized in that at least the functional layer (s) has a density or tensile strength, water permeability, and / or aesthetic properties that improve the acoustic, thermal or fire resistance properties of the sheet material, improve its density, improve material efficiency or production cost efficiency. and / or fillers.
  12. 13. Referring to FIGS. Sheet material according to any one of claims 1 to 3, characterized in that the starting material mixture contains the water-reducing additive (s) in an amount sufficient to retain the porosity of the functional layer (s) and the base layer to wet dewatering.
  13. 14. References 1-13. Sheet material according to any one of claims 1 to 4, characterized in that it contains particulate material (s) as the water-reducing additive (s).
  14. 15. Referring to Figures 1-14. A sheet material according to any one of claims 1 to 3, characterized in that the water-reducing additive or its components are selected from the group consisting of fly ash, aluminum oxide trihydrate, quartz flour, casting spheres or a mixture of two or more of the substances listed.
  15. 16. Examples 1-15. A sheet material according to any one of claims 1 to 3, characterized in that the coated product is matured after application of the coating by air or steam contact or by hydrothermal treatment in an autoclave.
  16. 17. References 1-16. Sheet material according to one of Claims 1 to 3, characterized in that the coated sheet or base layer is a sheet of construction material containing cement or gypsum as a hydraulic binder.
  17. 18. References 1-17. Sheet material according to one of Claims 1 to 5, characterized in that the thickness of the functional layer applied to the sheet or base layer is between 0.1 and 10 mm.
  18. 19. References 1-18. A sheet material according to any one of claims 1 to 4, characterized in that the hydraulic binder used in the starting material mixture of the coating material is selected from the group consisting of white, gray or pigmented cements, hydraulic lime or mixtures thereof.
    -1 920. 1-19 A sheet material according to any one of claims 1 to 3, characterized in that the hydraulic binder is present in the starting material mixture in a proportion of 10 to 50% by weight of the total amount of dry matter contained.
  19. 21. The method of 1-20. Sheet material according to any one of claims 1 to 3, characterized in that the water-reducing additive or at least one component thereof is a fly ash.
  20. 22. Referring to FIGS. The sheet material according to any one of claims 1 to 3, characterized in that the water-reducing additive is the first component of a particle diameter of between 1 and 100 μm in the proportion of 10 to 60% by weight of the total dry matter, while the total dry matter content is 5 to 30% by weight of the particles. the fly ash contains a second component with a maximum particle diameter of 10 μm.
  21. 23. The method of 1-22. Sheet material according to one of Claims 1 to 3, characterized in that the water-reducing additive contains a fly-ash fly with a particle size of more than 100 μm.
  22. 24. References 1-23. A sheet material according to any one of claims 1 to 3, characterized in that the functional layer comprises at least one additive (s) for treating the properties of the base layer by treating the base layer by treatment.
  23. 25. A method for producing a layered sheet material, especially for construction use, in particular a skeleton sheet material, comprising the step of producing an aqueous material mixture comprising a hydraulic binder and at least one water-reducing additive or additive, and applying the aqueous material mixture to the base layer on a functional layer. the functional layer is dewatered or dewatered, the aqueous material mixture preparation, application and dewatering steps are optionally cyclically repeated while the water content reducing additive (s) is (are) added to the aqueous material mixtures prepared as the starting material (s); it has sufficient porosity to drain the (functional) layer (s) of the functional layer (s) through the base layer and optionally further functional layer (s) therein; in heaven.
  24. 26. The method of claim 25, further comprising one or more functional additives that provide or improve the desired characteristics of said layer (s) for said aqueous layer (s) of said functional layer (s). added.
  25. 27. The method of claim 25 or 26, wherein the base layer is made of a skeletal base material.
  26. 28. The 25-27. Method according to one of Claims 1 to 3, characterized in that the base layer is made of a skeletal base material comprising a hydraulic binder, in particular cement.
  27. 29. The 25-28. Method according to one of Claims 1 to 3, characterized in that functional layers are applied to both sides of the base layer.
  28. 30. The 25-28. Method according to any one of claims 1 to 3, characterized in that functional layers are applied to only one side of the base layer.
  29. 31. The 25-30. Method according to any one of claims 1 to 3, characterized in that at least one functional additive suitable for producing or improving the desired characteristics of said layer is added to the starting material mixture of each functional layer (s).
  30. 32. Method according to one of Claims 1 to 3, characterized in that the functional layer (s) (z) (respectively) is coated with a stiffening layer.
  31. 33. The 25-32. Method according to any one of claims 1 to 3, characterized in that a fibrous web or web is used as the reinforcing layer (s).
  32. 34. The 25-33. A method according to any one of claims 1 to 3, characterized in that a fiber-skinned layer made of a starting material mixture comprising a cement binder, in particular a cement, is used as a stiffening layer.
  33. 35. The 25-34. Method according to one of Claims 1 to 3, characterized in that the layered sheet material is made from outer layers comprising a stiffening frame and a structure comprising at least one functional layer produced from a hydraulic binder, in particular a cement-containing starting material mixture.
  34. 36. Method according to one of Claims 1 to 3, characterized in that the fiber content of the fiber layer of the functional layer (s) is selected to be less than the fiber content (s) of the layer (s) of the layer (s) of starting material mixture comprising the hydraulic binder, in particular cement.
  35. 37. The 25-36. Method according to any one of claims 1 to 3, characterized in that the sheet material for the starting material composition of at least the functional layer (s) is
    -21 additive and / or filler materials that improve acoustic, thermal or fire resistance, density, material consumption or production cost efficiency, improve material efficiency, or water permeability, and / or aesthetic properties.
  36. 38. The 25-37. Method according to one of Claims 1 to 3, characterized in that the additive (s) for reducing the water content of the starting material mixture (s) is added to the functional layer (s) and the porosity of the base layer to an extent sufficient to maintain wet dewatering.
  37. 39. The 25-38. Method according to any one of claims 1 to 3, characterized in that particulate material (s) is used as the water-reducing additive (s).
  38. 40. Articles 25-39 A process according to any one of claims 1 to 3, characterized in that the water-reducing additive or components thereof are selected from the group consisting of fly-ash, aluminum oxide trihydrate, quartz flour, casting spheres or a mixture of two or more of the substances listed.
  39. 41. A method according to any one of claims 1 to 4, characterized in that the coated product or preform is aged by contact with air or steam or hydrothermal treatment in an autoclave after application of the coating.
  40. 42. The 25-41. Method according to one of Claims 1 to 3, characterized in that a sheet of construction sheet material containing cement or gypsum, in particular cement or gypsum plasterboard, is used as a coated binder or base layer.
  41. 43. The 25-42. Method according to any one of claims 1 to 3, characterized in that the thickness of the functional layer applied to the sheet or base layer is adjusted to a value between 0.1 and 10 mm.
  42. 44. The 25-43. Method according to one of claims 1 to 3, characterized in that the hydraulic binder used in the starting material mixture of the coating material is selected from the group consisting of white, gray or pigmented cements, hydraulic lime or mixtures thereof.
  43. 45. Process according to any one of claims 1 to 3, characterized in that in the starting material mixture, between 10 and 50 wt.
    • · · ·
    -22
  44. 46. The 25-45. A method according to any one of claims 1 to 3, characterized in that we use fly ash as a water-reducing additive or component.
  45. 47. The 25-46. Method according to one of Claims 1 to 5, characterized in that the total amount of dry matter in the starting material mixture (s) is 10-60% by weight of the fly ash as a first component of a particle diameter of 1 to 100 μm, while the total dry matter is 530% by weight. % of the fly ash also uses an additive (also) containing a second component with a particle diameter of up to 10 μm.
  46. 48. Method according to any one of claims 1 to 3, characterized in that the water-reducing additive used in the starting material mixture (s) for its execution comprises a coarse fly ash fraction (also) with a particle diameter greater than 100 µm.
  47. 49. The 25-48. Method according to one of Claims 1 to 4, characterized in that the at least one functional layer comprises at least one additive (s) for treating the properties of the base layer by treating the base layer by treatment with the base layer.
  48. 50. The 25-49. Method according to one of Claims 1 to 3, characterized in that the aqueous starting material mixture of the at least one functional layer is applied to the base layer by means of a spray application method / apparatus.
    The proxy
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AUPR3478A AUPR347801A0 (en) 2001-03-02 2001-03-02 Coatings for building products
AUPR3476A AUPR347601A0 (en) 2001-03-02 2001-03-02 Additive for dewaterable slurry
AUPR3475A AUPR347501A0 (en) 2001-03-02 2001-03-02 Spattering apparatus
AUPR3477A AUPR347701A0 (en) 2001-03-02 2001-03-02 A method and apparatus for forming a laminated sheet material by spattering
AUPR3474A AUPR347401A0 (en) 2001-03-02 2001-03-02 A composite product
PCT/AU2002/000241 WO2002070247A1 (en) 2001-03-02 2002-03-04 A composite product

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HU0303320A HU0303320A3 (en) 2001-03-02 2002-03-04 A composite product
HU0303328A HU0303328A3 (en) 2001-03-02 2002-03-04 Additive for dewaterable slurry
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AUPQ468299A0 (en) * 1999-12-15 2000-01-20 James Hardie Research Pty Limited Method and apparatus for extruding cementitious articles
WO2001068547A1 (en) 2000-03-14 2001-09-20 James Hardie Research Pty Limited Fiber cement building materials with low density additives
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