JPH07500058A - Composite structure with foamed plastic core material and its manufacturing method - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed description of the invention] Composite structure with foamed plastic core material and its manufacturing method 11th stand 1j 1 lesson TECHNICAL FIELD This invention relates generally to composite structural materials and methods of manufacturing the same, and more specifically to inflatable materials. Constructed from lightweight expanded foam plastic such as stretched polystyrene A lightweight, fire-resistant composite material with a core material that can be manufactured at low cost, and its manufacturing method. related. The core material has one or more of its surfaces coated with a cement slurry binder. Consisting of one or more layers of nonwoven fabric impregnated or impregnated with The fibers within the material layer form a three-dimensional reinforcing matrix for the cement slurry. covered by a strong outer layer. This outer layer is made of lightweight plastic. Formed and hardened on one or more surfaces of the core material, it is a common cement or concrete material. It has greater flexibility and tenacity than REET, and is more resistant to cracking.

The cement in the outer layer is bonded directly to the lightweight plastic core, thus adding No special bonding material required. The outer layer can be used in a variety of ways for different end uses. It can be formed around a shaped core and cured.

Aki J” 1 jutsu o1 Tomo Composite materials consist of a strong outer layer bonded to a lightweight core material. used for various purposes.

This outer layer provides the composite with strength, durability, UV resistance, fire resistance, and resistance, depending on the application. It acts to enhance chemical properties or a combination of these properties.

U.S. Pat. No. 4,764,238 discloses that fibers pre-impregnated with a thermosetting resin are heated. By applying pressure and bonding these fibers to a foam core material with open holes. A manufactured composite material is disclosed. The resulting lightweight composite material It is said to be suitable for impact-resistant structures that absorb energy.

U.S. Pat. No. 4,050,659 discloses that Electrical transformer formed with an outer plastic surface reinforced with glass fibers Regarding rugs.

U.S. Pat. No. 4,303,722 discloses a glass fiber woven or cloth-like body and a heat-cured It is composed of a composite of hardened polyester condensation resin and plaster, and is a foamed plastic material. Panels with a thin surface finish bonded to a rigid, non-flexible substrate such as It is listed. In this composite, the fibers in the reinforcement are essentially two-dimensional and It is convenient to place it as close as possible to the surface of the finishing layer.

U.S. Pat. No. 4,963,408 discloses a durable material reinforced by oriented fibers. A monolith produced by wrapping a foam core in a load-bearing polymeric matrix related to composite laminated structures. This composite material also has a Use a binding material for this purpose.

U.S. Pat. No. 4,559,263 discloses that one side of an expanded foam panel has a lightweight Cement bonded with concrete made with aggregate and foaming agent - foamed material Describe the composite board. The patent further describes unspecified reinforcement means for concrete 1. It is said that it may be included.

Panels produced in the manner described above are subject to the selection of materials used for the coating or finishing layer. Their performance is limited by the trade-off between two non-simultaneous conditions in be done. Resin and polymer coatings have less fire resistance than cementitious coatings. The cost of manufacturing will be high.

However, the cementitious finish layer has low bending strength and is prone to cracking and crumbling. Easy to use.

For thin sheets of material, the strength against the cement matrix is Non-woven fibers have been used as synthetic materials.

U.S. Pat. No. 4,778,718 describes dry cement in a matrix of fibers. After daubing, by adding water and hydrating the cement to form a sheet. A sheet of cement reinforced with non-woven fabric is described.

U.S. Pat. No. 4,617,219 discloses at least one non-woven material as a fibrous reinforcement. Concerning the construction of three-dimensionally reinforced cement using woven fabrics. This patent is further by forming layers of such cement sheets together, reinforced by non-woven fabrics. It is said that it can be used to make architectural panels.

Thin, coreless sheets produced using the method described above can be stretched at typical panel lengths. It must have sufficient overall strength to support loads such as wind or foot traffic. stomach. This thin coreless sheet has outstanding insulation properties compared to regular concrete. It does not show great insulation properties. The above method can support the load without a lightweight core material. Panels built to sufficient thickness will be as good as equivalent panels made of regular concrete. 17 is not light by about 30%.

Polystyrene is used as a buoyant support for floating structures such as boat docks. A lightweight foamed plastic block is used. These blocks are When used without a protective outer layer, chemicals in the water from an outboard motor, for example, can It can fray the lock, and block fragments can then drift and pollute the water. dye.

l scallop 1j One object of the invention is to be lightweight, inexpensive to manufacture, flexible, and resistant to cracking. The objective is to provide a composite material that is both strong and fire resistant.

Another object of the invention is to reduce the number of plywood, floating docks, building panels, noise meeting end-use requirements such as damping surfaces and insulation with its own fire-resistant coating. It is an object of the present invention to provide a method for manufacturing this composite material in a form suitable for addition.

This composite material is formed around one or more sides of a lightweight core material and is hardened. It consists of a strong outer layer. This outer layer is three-dimensionally reinforced with non-woven fibers. It is a matrix of cement. The fibers are present at a volume filling factor of 3-20% gives the outer layer greater bending strength, flexibility, tenacity, and crack resistance. . The fibers are completely encapsulated within the cement matrix and are transparent to the outer layer. Gives the good appearance, hardness and durability of regular concrete. Fibers can also be Protected from fire and UV rays by a matrix of UV rays.

This outer layer is formed while the cement matrix is in a water-containing, uncured state. It is applied to a core material, preferably expanded polystyrene. The outer layer contains water In order to uniformly distribute the cement matrix throughout the fiber entanglement, , and to allow the outer layer to bond to the core material as the matrix hardens. To ensure even contact of the sea urchin cement matrix with the lightweight core material, manual or can be applied by mechanical pressing means.

The use of a lightweight foamed plastic core provides an increased strength to weight ratio. child This is a result of the sandwich panel beam design and the large bending strength of the outer layer. It appears in the bending that binds. In compaction, this composite material It has great strength, thanks to the compressive strength of the outer layer, which is comparable to that of steel sheets.

When used for support of floating structures, the outer layer of this composite material is the first It protects the polystyrene core from chemicals that can damage it, and also protects the Prevents pieces of core material from breaking off and polluting the marine environment.

These objectives, along with other objectives and benefits that will become apparent later, are and the details of construction and operation hereinafter described and claimed. Same number throughout the scheme Reference is made to the accompanying drawings in which the numbers refer to the same parts.

nona 9th FIG. 1 is a perspective view of a panel utilizing the composite structural material of the present invention.

FIG. 2 is an enlarged view showing a particular configuration of elements forming the composite structural material of the present invention. FIG.

FIG. 3 is a perspective view of a buoyant support for a floating structure such as a boat dock. .

A beautiful day Referring to the drawings, a composite structural material in the form of panels is shown in FIG. The entire amount is indicated by the reference numeral 10. and generally designated by the reference numeral 12. the top of both the core material and one or opposite surfaces of the panel. or globally, which may extend around all edges and all surfaces. It includes an outer layer designated by the numeral 14. These outer layers 14 are connected to the inner surface of the panel. External appearance to form the exterior surface and achieve the desired architectural finish characteristics. Various materials such as plastics when used for purposes, forming or finishing Texture and color can be added by coating, painting, grooving, etc. 　

As shown in FIG. 2, the core material 12 includes a plate 16. in the form of blocks or other structural materials It is made from lightweight foamed plastic, such as expanded polystyrene.

Outer layer 14 includes unwoven fibers 20 with a fiber amount ranging from 3 to 20%. It includes a three-dimensional network 18 of non-woven fabric. Cement slurry (fine solid particles The binder 22 (suspended in the body) holds the fibers 20 closely together as it hardens. It surrounds the fibers, penetrates between them, and binds them together. of cement within this outer layer. The slurry binder 22 includes the hardened slurry binder 22, the outer layer 14, and the hardened slurry binder 22. The fibers are cured together with the nonwoven fibers 20 and the core material 12 to form a rigid one piece. stop It has an extremely light core and is reinforced and stiffened by one or more outer layers. a panel in which the core and one or more outer layers rigidly form one rigid unit. provide.

In one embodiment of the invention, one panel is inflated according to the invention. It was formed by using a polystyrene plate 16. cement slurry , were mixed in a portable mortar mixer in the following weight ratios:

10 parts Portland cement, 1 part fine silica, 5 parts fine sand, 4 parts water, and 0°1 part of superplasticizer reduced with water. Open needle holes weighing 8 ounces per square yard. A sheet of nonwoven polypropylene with a 4-inch loft per section, It is cut into several pieces just the right size to cover the board, and the cement slurry is added to the wet It is applied by hand or mechanical press in an uncured state and then pasted onto the core material. Ta.

After 24 hours of curing, test beams were cut from this panel. These tests The beam was 24 inches long, 6 inches wide and 2.5 inches thick.

These test beams had an 18-inch span (distance between supports) after a 7-day cure period. The bending strength is measured by using a third point load at was 500 psi. This bending strength is approximately 20 pounds per square foot. approximately equivalent to prior art panels when made 4 inches thick, weighing Ru.

This lightweight, inexpensive to manufacture, heat-insulating, fire-resistant, chemical-resistant, UV-resistant and The flexible structure means that this composite material can be used as a base to support the equipment or as plywood, fireproof and soundproof. panels, building panels, self-coated insulation for vibes and conduits, docks This structural material allows the dock to be used as a float to support the Provides sufficient buoyancy to support the water while floating at the desired height, and provides ultraviolet rays. Highly resistant to deterioration caused by

The foregoing is considered only as a detailed description of the invention. Further in this field Since numerous modifications and variations will readily occur to those skilled in the art, the present invention has been shown in more detail. It is not desired to be limited to the exact construction and operation described and, therefore, All suitable modifications and equivalents are deemed to be included within the scope of the invention.

Continuation of front page (81) Designated countries EP (AT, BE, CH, DE.

DK, ES, FR, GB, GR, IT, LU, MC, NL, SE), 0A (BF , BJ, CF, CG, CI, CM, GA, GN, ML, MR, SN, TD, TG. ), AU, BB, BG, BR, CA, C3, FI, HU: JP.

KP, KR, LK, MG, MN, MW, No, PL, RO, RU, SD

Claims (7)

[Claims] 1. Core material made from a lightweight, low-density, virtually unbendable material and reinforced with fibers. an outer layer formed from a binder made of cement slurry; is applied to the core material and allowed to harden, and a binder consisting of a cement slurry is applied to the core material. A rigid, unbendable matrix that extends virtually continuously over the entire outer surface. forming a lightweight material with great tenacity, crack resistance and flexibility. Composite materials that can be manufactured cheaply, have high strength, thermal insulation properties, and fire resistance. Forming, composite construction materials. 2. Claim 1, wherein said lightweight core material is formed from expanded polystyrene. Composite material as described. 3. The expanded polystyrene is in the form of a substantially rigid and unbendable plate. Composite material according to claim 1. 4. The composite material according to claim 1, wherein the reinforcing fibers of the outer layer are in the form of a nonwoven fabric. 5. The above-mentioned core material is divided into two flat core materials to form a sandwich panel. A composite material according to claim 1 having two outer layers formed on a surface. 6. Composite material according to claim 2, wherein the reinforcing fibers of the outer layer are in the form of a non-woven fabric. 7. Forming the core material of a lightweight board that is substantially vertical and unbendable, made from a low-density material. step, the above core material is made from a cement slurry containing Portland cement. applying the binder, water and additives, if the binder still contains water. a step of adding a fibrous layer in the form of a non-woven fabric to the binder while it is still uncured; each step of applying pressure to the outer layer to harden the material and form the composite material. A method of manufacturing a composite material consisting of