NZ719711A - Composite board comprising magnesium oxide and magnesium chloride - Google Patents
Composite board comprising magnesium oxide and magnesium chloride Download PDFInfo
- Publication number
- NZ719711A NZ719711A NZ719711A NZ71971114A NZ719711A NZ 719711 A NZ719711 A NZ 719711A NZ 719711 A NZ719711 A NZ 719711A NZ 71971114 A NZ71971114 A NZ 71971114A NZ 719711 A NZ719711 A NZ 719711A
- Authority
- NZ
- New Zealand
- Prior art keywords
- layer
- mould
- volume
- main body
- composition
- Prior art date
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- 239000002131 composite material Substances 0.000 title claims abstract description 26
- 239000000395 magnesium oxide Substances 0.000 title claims abstract description 19
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 title claims abstract description 19
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 title claims abstract description 18
- TWRXJAOTZQYOKJ-UHFFFAOYSA-L Magnesium chloride Chemical compound [Mg+2].[Cl-].[Cl-] TWRXJAOTZQYOKJ-UHFFFAOYSA-L 0.000 title claims abstract description 14
- 229910001629 magnesium chloride Inorganic materials 0.000 title claims abstract description 7
- 239000000203 mixture Substances 0.000 claims abstract description 53
- 239000002002 slurry Substances 0.000 claims abstract description 32
- 239000007787 solid Substances 0.000 claims abstract description 29
- 239000007864 aqueous solution Substances 0.000 claims abstract description 21
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 17
- 238000000034 method Methods 0.000 claims abstract description 15
- 239000000463 material Substances 0.000 claims abstract description 12
- 239000000843 powder Substances 0.000 claims abstract description 12
- 239000000945 filler Substances 0.000 claims abstract description 6
- 238000004320 controlled atmosphere Methods 0.000 claims abstract description 3
- 239000012535 impurity Substances 0.000 claims description 7
- 150000004760 silicates Chemical class 0.000 claims 1
- 239000004744 fabric Substances 0.000 abstract description 18
- 239000003063 flame retardant Substances 0.000 abstract description 3
- 238000010943 off-gassing Methods 0.000 abstract 1
- 239000010410 layer Substances 0.000 description 47
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 18
- 239000000047 product Substances 0.000 description 12
- 238000005253 cladding Methods 0.000 description 9
- 239000000243 solution Substances 0.000 description 7
- 238000001723 curing Methods 0.000 description 6
- 239000011152 fibreglass Substances 0.000 description 6
- 239000005995 Aluminium silicate Substances 0.000 description 5
- 235000012211 aluminium silicate Nutrition 0.000 description 5
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 5
- 239000004568 cement Substances 0.000 description 4
- 239000004115 Sodium Silicate Substances 0.000 description 3
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 3
- 239000004327 boric acid Substances 0.000 description 3
- 230000009970 fire resistant effect Effects 0.000 description 3
- 239000003517 fume Substances 0.000 description 3
- 238000013007 heat curing Methods 0.000 description 3
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 3
- 229910052911 sodium silicate Inorganic materials 0.000 description 3
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 2
- 241000209094 Oryza Species 0.000 description 2
- 235000007164 Oryza sativa Nutrition 0.000 description 2
- 239000011324 bead Substances 0.000 description 2
- 239000004566 building material Substances 0.000 description 2
- 229940043430 calcium compound Drugs 0.000 description 2
- 150000001674 calcium compounds Chemical class 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 239000000975 dye Substances 0.000 description 2
- 239000010903 husk Substances 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- 229910052749 magnesium Inorganic materials 0.000 description 2
- 229920006327 polystyrene foam Polymers 0.000 description 2
- 235000009566 rice Nutrition 0.000 description 2
- 239000011734 sodium Substances 0.000 description 2
- 229910052708 sodium Inorganic materials 0.000 description 2
- 231100000331 toxic Toxicity 0.000 description 2
- 230000002588 toxic effect Effects 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- 239000010425 asbestos Substances 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 239000002537 cosmetic Substances 0.000 description 1
- 230000007717 exclusion Effects 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
- 239000001095 magnesium carbonate Substances 0.000 description 1
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 1
- 239000010451 perlite Substances 0.000 description 1
- 235000019362 perlite Nutrition 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- 238000006748 scratching Methods 0.000 description 1
- 230000002393 scratching effect Effects 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 235000015112 vegetable and seed oil Nutrition 0.000 description 1
- 239000008158 vegetable oil Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
- B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
- B28B1/008—Producing shaped prefabricated articles from the material made from two or more materials having different characteristics or properties
-
- 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
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/0006—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects the reinforcement consisting of aligned, non-metal reinforcing elements
-
- 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
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/12—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein one or more rollers exert pressure on the material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
- B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/30—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing magnesium cements or similar cements
- C04B28/32—Magnesium oxychloride cements, e.g. Sorel cement
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K21/00—Fireproofing materials
- C09K21/02—Inorganic materials
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/92—Protection against other undesired influences or dangers
- E04B1/94—Protection against other undesired influences or dangers against fire
- E04B1/941—Building elements specially adapted therefor
- E04B1/942—Building elements specially adapted therefor slab-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
- E04C2/06—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres reinforced
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2419/00—Buildings or parts thereof
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Abstract
A method of forming a composite board is disclosed, comprising steps of providing a mould, preparing pouring and spreading a layer of facing composition having at least 59wt% magnesium oxide powder and optional components in an aqueous solution of MgCl2, with at least one woven cloth reinforcing sheet layer contained in the layer; preparing, pouring and spreading a main body composition comprising a pourable and spreadable slurry of a solid component including 7% to 40% by volume magnesium oxide, 10% to 85% by volume of a particulate cellulosic material, and from 5% to 40% by volume of a non-cellulosic lightening filler, in an aqueous solution of MgCl2; and placing and containing said mould in a controlled atmosphere to cure and dry. The composite board produced according to the method exhibits improved flame resistance and fire retardant properties and reduced off-gassing of harmful vapours in a fire event, compared with hitherto known plasterboard sheets and composite panels.
Description
COMPOSITE BOARD COMPRISING IUM OXIDE AND MAGNESIUM
CHLORIDE
Technical Field
This invention relates to a board for use as a ng material as a
cladding or internal wall sheet material. The fnvention provides in one
embodiment, a sheet material of composite construction, having some
ageous properties.
Background Art
The following discussion of the ound art is intended to facilitate an
understanding of the present invention only. It should be appreciated that the
discussion is not an acknowledgement or admission that any of the material
referred to was part of the common general knowledge as at the priority date of
the application.
Plasterboard such as that sold as Gyprock TM, also composite cement
fibreboard which formerly was an asbestos cement product, have been used as
building materials as cladding and sheeting for internal wans. Cement oard
has been used for external wall and under-eve cladding, due to Its superior
weathering characteristics; whereas plasterboard is used as an Internal wall
cladding. Neither of these building materials are particularly fire retardantt and
cement fibreboard is known to spall when heated.
Throughout the specification unless the context requires otherwise, the
word "comprise" or ions such as "comprises" or "comprising", will be
tood to imply the inclusion of a stated integer or group of rs but not
the exclusion of any other integer or group of rs.
Summary of Invention
It is an object of this invention to provide a composite board having fire
retardant properties.
In accordance with one aspect of the present invention there is provided
a method of forming a composite board, comprising the following steps:
providing a mould into which the composite board ls to be formed;
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preparing a facing composition sing a pourable and spreadable
slurry of a solid component including at least 59% by weight magnesium oxide
powder, optional components, and inert impurities, and a first aqueous solution of
MgCh at S.G. of from 1.05 to 1.20;
preparing a main body composition comprising a le and spreadable
slurry of a solid component including 7% to 40% by volume magnesium oxide,
% to 85% by volume of a ulate cellulosic material, and from 5% to 40%
by volume of a non-cellulosic ning filler, and a second aqueous solution of
MgCh at S.G. of from 1.05 to 1.20;
pouring the facing composition into said mould and spreading the facing
composition substantially evenly in said moufd with at least one woven cloth
reinforcing sheet layer contained therein or thereonneIn a first layer to a thickness
of from about 1 mm to 6 mm;
pouring the main body composition into said mould and spreading the
main body composition on top of said first layert in a second layer to a thickness
of from about 3 mm;
placing and containing said mould in a controlled atmosphere to cure and
eane
Inert impurities included in the solid component would lly include
impurities included in the magnesium oxide component. These vary depending on
the source of the MgO, and may include other magnesium components, calcium
compounds, and iron containing ties.
Preferably the facing composition is poured in a first layer to a thickness
of from about 1 mm to 5mm,
Preferably the facing composition is poured in a first layer to a thickness
of from about 1 mm to 4mm.
Preferably the facing composition is poured in a first layer to a thickness
of from about 1 mm to 3mm.
[OOH] ably the facing composition is poured in a first layer to a thickness
of from about 1.5 mm to 3mm.
PCTIAU2014/050280
Preferably the facing composition is poured in a first layer to a thickness
of In the order of anywhere between 1.5 mm, 2 mm, 2,5 mm and 3mm.
Preferably said facing composition solid component comprises at least
85% by weight of magnesium oxide of at least 70% purity. However, it is most
preferred that the magnesium oxide has a purity in the range of 97% to 99%.
Preferably said facing composition solid component includes up to 15% by
weight of one or more dry hydrated smcates. These may be ed from days
ing kaolin. The inclusion of this ent imparts improved flexibility to
the composite board.
Preferably said facing composition solid ent includes up to 15% by
weight of kaolin.
Preferably said facing composition solid component includes up to 5% by
weight of aluminium oxide powder.
Preferably said facing composition solid component indudes up to 4% by
weight of aluminium oxide powder,
Preferably said facing composition solid component includes up to 3% by
weight of aluminium oxide powder.
Other optional ents may include carbon, colourants and dyes.
Preferably said first aqueous solution has en S.G. of from about 1.11 to
1.19.
(0021] Preferably said first aqueous solution has an S.G. of from about 1.12 to
1.18,
Preferably said first aqueous solution has an S,G, of from about 1.13 to
1.17.
Preferably said first s solution has an S.G. of from about 1.14 to
1.16.
Preferably said first aqueous solution has an S.G. of about 1.15 to 1.17.
[002.5] Preferably said first aqueous solution includes up to 15% by volume of
sodium sHicate. The on of sodium silicate reduces porosity of the cured
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????
composite board, improves water resistance of the composite board, and aids in
the curing process.
Preferably said first aqueous solution includes up to 10% by volume of
sodium silicate,
The proportion of solid component to first aqueous solution ls about 1.8: 1
to 1. 5: 1 by weight, and most preferably about 1.6: 1.
Preferably said second aqueous solution has an S.G. of from about 1.11
to 1.19.
Preferably said second aqueous solution has an S.G. of from about 1.12
to 1.18.
(0030] Preferably said second aqueous solution has an S.G. of from about 1.13
tu 1.17.
Preferably said second aqueous on has an S.G. of from about 1.14
to 1.16.
Preferably said second aqueous solution has an S.G. of about 1.15 to
1.17.
Preferably said second aqueous solution includes up to 15% by volume of
sodium te.
Preferably said second aqueous solution es up to 10% by volume of
sodium silicate.
Preferably the woven cloth reinforcing sheet layer is a woven fibreglass
mesh.
(0036] Preferably there is one woven cloth reinforcing sheet layer contained
within the facing composition layer.
ably there are two woven cloth reinforcing sheet !ayers contained
within the facing ition layer.
Alternatively or additionally, preferably there may be one woven cloth
reinforcing sheet layer at the boundary of the facing composition layer and the
main body composition layer.
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????
Preferably there is one woven cloth reinforcing sheet layer ned
within the facing composition layer( and one woven doth reinforcing sheet layer
at the boundary of the facing composition layer and the main body ition
layer.
Preferably there is provided at least one woven cloth reinforcing sheet
layer ned within said main body composition.
Preferably said main body ition includes from 80/o to 35% by
volume of magnesium oxide.
Preferably said main body composition includes from 9 to 30% by volume
of magnesium oxfde.
Preferably said main body composition includes from 10% to 20% by
volume of magnesfum oxide,
ably said main body composition includes from 12% to 18% by
volume of magnesium oxide.
[0045) Preferably said main body composition includes from 40% to 80% by
volume of said particulate cellulosic material.
ably said main body composition includes from 50% to 75% by
volume of said particulate ceUulosic material.
Preferably said main body composition includes from 60% to 75% by
volume of said particulate cellulosic material.
Preferably said particulate celluloslc material is selected from sawdust,
wood chips, bark chips, by-products of cropping including husks and hulls.
[00491 Preferably said main body ition includes by volume from 5% to
% of rice husk as part of said particulate cellulosic material.
Preferably said main body composition includes from 8% to 30% by
volume of said non-cellulosic tightening fi!fer.
(0051] Preferably said main body composition includes from 10% to 20% by
volume of said non-cellulosic lightening filler.
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????
Preferably said main body composition includes about 15% by volume of
said llulosic lightening filler.
Preferably said non-cellulosic lightening f!ller is selected from one or more
of expanded e, expanded foam polymer beads such as polystyrene foam
beads. The non-cellulosic lightening filler acts to reduce the weight of the finished
product.
Preferably said main body composition solid component es up to
% by volume of one of more dry hydrated silicate itions. These may be
selected from clays including kaolin.
Preferably said main bod)' composition solid component includes up to
8% by volume of kaolin.
ably said main body composition solid component includes up to
% by volume of kaolin.
Preferably said main body ition solid ent includes up to
% by volume of ium oxide powder.
Preferably said rnain body composition solid component includes up to
4% by volume of aluminium oxide powder.
Preferably said main body composition solid component includes up to
3% by volume of aluminium oxide powder.
(0060] Preferably said main body composition solid component includes up to
1% by volume of boric acid.
Preferably said main body composition solid component includes about
0,5% by volume of boric acid.
The proportion of solid component to second aqueous solution is about
1.8:1 to 1.5:1, and most preferably about 1.6:1; however, the exact amount
depends on the moisture component of the dry ingredients.
Preferably 00prior to placing the mould in a kiln for the wet composition
board to cure and dry, an additional step is included comprising placing a single
layer of fabric on the exposed surface of the slurry forming the main body
composition, to bond therewith. This may comprise n or another similar
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soft woven fabric; and provides a soft surface so that cured composite board can
be stacked once extracted from the mould, without scratching the surface of the
facing composition.
Preferably also before g the mould in a kiln for the wet ition
board to cure and dry, a further onal step is included comprising
compressing the d board with at least one roller to extrude excess
thickness and provide a uniform thickness in the product prlor to curing.
Preferably the step of placing and ning said mould in a controlted
atmosphere to cure and dry comprises placing the mould in an atmosphere having
a temperature of from 30 degrees s to 50 degrees Celsius for a nominal 12
hour period. Following this, preferably the cured product is separated from the
moulds, and the cured product is subject to a further low ature (at 25
degrees s low humidity curing process for a nominal period of one week.
The kiln drying is a low temperature operation, at 30 degrees Celsius for
about 12 hours. This time would be increased If a lower temperature is used.
The important point 1s not to drive off the excess moisture before full curing has
taken place.
On curing and drying of the composite board it is removed from the
moulds and has its edges d to the required board size.
Also in accordance with the invention there is provided a composite panef
product made in accordance with the above described method.
Further, in accordance with the invention there is provided a composite
building product having a facing layer formed from a facing composrtion
sing a pourable and spreadable slurry of a solid component including at
least 59% by weight magnesium oxide powder, optional components, and inert
impurities, and a first aqueous solution of MgCl2 at S.G. of from 1.05 to 1.20,
spread to a thickness of from 1 mm to 6 mm and having at feast one woven doth
reinforcing sheet layer contained therein.
Description of Embodiments
iwo preferred embodiments will now be described in the following
description of a process for producing a fire resistant composite board for use in
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external and internal cladding for waits and ceilings in buHdings. The ed
cladding product comprises sheets of 3.9 metres x 1.2 metres, and 8 mm thick.
To make the cladding product, a mould of 4.0 metres x 1.3 metres is
provided, with sides to contain the slurry used in the method. The mould is faid
on a horizontal s1,.1rface so that the slurry does not flow which would result in an
uneven thickness in the completed composite board. The mould surface is
lubricated with a vegetable oil mould release agent, prior to commencing the first
pour.
A solution of magnesium chloride is prepared having a specific gravity of
1.17.
A facing surface slurry is then made using some of the solution. The
facing surface slurry comprises 98% by weight of reactive magnesium oxide
powder and 2% by weight aluminium oxide, mixed in a mixing vessel with an
auger prior to adding the solution, with mixing, to form a slurry. The total weight
of solids required for the facing surface slurry for a single 4 metre x 1. 3 metre
mould will depend on the actual thickness required in the facing surface layer.
Nine litres of solution is added for every 16 kg of solid. The magnesium oxide
powder is calcined te, and may contain impurities sing magnesium
carbonate, calcium compounds (oxide, ate, and chloride, and ferric
impurities.
A main body slurry is made comprising by volume, 14% reactive
magnesium oxide, 64.5% dry sawdust, 15% expanded e, 6% rice hull, and
0.5% boric acid also mixed in a mixing vessel with an auger, before solution is
added to form a slurry, The weight of solids required for the main body slurry for
a single 4 metre x 1.3 metre mould will depend on the actual thickness requlred
in the main body layer. The slurry of the main body is of thicker paste like
consistency than the facing surface , In practice the amount of solution
required to form the main body slurry is determined by the moisture content in
the solids.
The slurries are both ed on a just-in-time basis, since the hydraulic
setting process will commence, and for obvious reasons it is necessary that the
curing process take place in the mould as opposed to in the mixing vessel.
?????????????????????????????? ??????????????????????????????????
????
After the application of mould release into the mould, a layer of finishing
slurry is spread to a nominal 3mm thickness. This is ed by the placement of
a layer of reinforcing in the form of fibreglass woven eeneeeeiiaae application of
lightly weighted wiper which is wiped across the surface to smooth the cloth level,
contacting the doth with the slurry and excluding air. A further layer of finishing
slurry is spread to a nominal 3mm thickness. This is followed by the placement of
a fayer of reinforcing in the form of fibreglass woven cloth, with ation of a
lightly weighted wiper which is wiped across the surface to smooth the cloth level,
contacting the doth with the slurry to excluding air.
This is immediately followed by the application of a layer of main body
slurry of nominal 3mm thickness, followed by lying a layer of soft cloth onto the
top. To provide a uniform thickness in the completed composite board, while
contained in the mould the boards are pushed through a rollert with excess slurry
being pushed out at the sides.
The boards are taken to a heat curing room where they are held at a
nt ature of from 30°C to 50°C, lly 40°C for 12 hours before
being separated from the mould, stacked standing on their ends, and subjected to
heat curing for a r week at a constant temperature of 25°C at low ty.
The ite boards are them trimmed to the required size.
It aanebe understood that while a composite board having two reinforcing
weave layers is disclosed with a first weave layer within the finishing layer and
another at the boundary of the finishing layer and the main body layer, other
arrangements including the addition of a r weave layer within the main body
layer are possible. The particular embodiment bed is intended for a wall
cladding. The thickness described is intended for Internal use, and a thicker
cladding (by making the main body thickness greater( ally with a layer of
fibreglass cloth reinforcing contained within) t might be considered more secure for
external use. The composite panel according to the invention is fire resistant, and
also will not evolve dangerous fumes when heated. In contrast, competing
products promoted as being fire resistant tend to evolve toxic fumes that
overcome occupants of a building in which they are used.
A second embod1ment comprises a 3 mm nomlnal thickness layer of
facing slurry poured and spread into the mould, This is followed by the placement
of a layer of reinforcing in the form of fibreglass woven doth, with appllcation of
lightly weighted w1per which is wiped across the surface to smooth the doth level,
?????????????????????????????? ??????????????????????????????????
??????
contacting the cloth with the slurry and excluding air. A layer of main body slurry
ls spread to a nominal 3mm thickness. This is followed by the placement of a
layer of reinforcing in the form of fibreglass woven cloth, with application of a
leeaeissweighted wiper which is wiped across the e to smooth the cloth level,
contacting the doth with the slurry to excluding air.
This is immediately followed by the application of a further layer of main
body slurry of l 3mm thickness, followed by lying a layer of soft doth onto
the top. Again, to provide a uniform ess in the completed composite board,
while contained in the mould the boards are pushed h a roller, with excess
slurry being pushed out at the sides.
Heat curing Is then undertaken as described for the first embodiment.
The board of the second embodiment has a lighter weight than that of the first,
while retaining the heat resistance and fire retardant properties.
In a fire, the boards of both embodiments produce a much lower level of
toxic fumes than known bulldlng panels, improving the prospects for nts
surviving a fire, providing that the fire does not take hold within the room clad by
board according to the embodiments. The facing layer side of the board Is that
which is on the outside of any wall construction, whether external or internal. The
cloth layer will be internal and will abut face any internal studs in a wall or joists
in a ceiling eaforming building frame work.
It will be understood that various changes may be made to some of the
components within the mix. Increasing the cellulose content s in a product
that is more machinable. Colorants and dyes may be added to the slurries for
cosmetic purposes. Expanded perlite and polystyrene foam s may be
added in the main body layer, ularly where a thicker layer in the main body
is ed, to reduce the weight of the completed panel.
Other moulded products are possible utilising the method disclosed for
the composite panel, such as corrugated panels and roofing tiles.
PCTIAU2014/050280
Claims (4)
1. A method of forming a composite boardt comprising the following steps: ing a mould into which the composite board is to be formed; preparing a facing composition comprising a pourable and spreadable slurry of a solid component ing at least 59% by weight magnesium oxide powder, optional componentst and inert impurities, and a first aqueous solution of MgCb at S.G. of from 1.05 to L20; preparing a main body composition comprising a pourable and spreadable slurry of a solid component ing 7% to 40% by volume magnesium oxide, 10% to 85% by volume of a ulate cellulosic material, and from 5% to 40% by volume of a non-ce!lulosic llghtening filler, and a second aqueous solution of MgCl2 at S.G. of from 1.05 to 1.20; g the facing composition into said mould and spreading the facing composition substantially evenly in said mould with at least one woven doth reinforcing sheet layer contained therein or thereon, in a first layer to a thickness of from about 1 mm to 6mm; pouring the main body composition into said mould and spreading the main body composition on top of said first layer, in a second layer to a thickness of from about 3 mm; and placing and containing satd mould in a controlled atmosphere to cure and dry.
2. A method as claimed in claim 1 wherein said facing composition solid component comprises at least 850/c, by weight of magnesium oxide of at least 70% purity.
3. A method as d in claim 2 wherein safd magnesium oxide has a purity in the range of 97% to 99%.
4. A method as claimed in any one of the preceding claims wherein said facing composition solid component includes up to 15% by weight of one or more dry hydrated silicates. PCTIAU
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2013903908A AU2013903908A0 (en) | 2013-10-10 | Composite Board | |
| PCT/AU2014/050280 WO2015051419A1 (en) | 2013-10-10 | 2014-10-10 | Composite board comprising magnesium oxide and magnesium chloride |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| NZ719711A true NZ719711A (en) | 2021-07-30 |
Family
ID=52812371
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| NZ719711A NZ719711A (en) | 2013-10-10 | 2014-10-10 | Composite board comprising magnesium oxide and magnesium chloride |
Country Status (3)
| Country | Link |
|---|---|
| AU (1) | AU2014334513B2 (en) |
| NZ (1) | NZ719711A (en) |
| WO (1) | WO2015051419A1 (en) |
Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2018130729A1 (en) * | 2017-01-12 | 2018-07-19 | Euro Trade Flooring, S.L. | Plate for covering horizontal and vertical surfaces |
| CN106836533B (en) * | 2017-01-20 | 2019-04-02 | 孟庆兴 | A kind of manufacturing method of light-weight water-proof fire-resistant insulating composite board |
| WO2018195599A1 (en) * | 2017-04-28 | 2018-11-01 | One Stop Marketing Solutions Pty Ltd | Composite panel |
| NL2019108B1 (en) * | 2017-06-22 | 2019-01-07 | Champion Link Int Corp | Floor panel and method of producing such a floor panel |
| CN109053125A (en) * | 2018-08-29 | 2018-12-21 | 孙杰 | A kind of mineral powder binding fiber composite board and production method and application |
Family Cites Families (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB291647A (en) * | 1927-08-20 | 1928-06-07 | Sima Minache | Building unit |
| US3963849A (en) * | 1971-11-01 | 1976-06-15 | Thompson Chemicals, Inc. | Fireproof product using magnesium oxychloride cement |
| GB1390595A (en) * | 1973-02-26 | 1975-04-16 | Danielis J | Lightweight decorative facing sheet material and method and composition for its preparation |
| US4203255A (en) * | 1977-05-26 | 1980-05-20 | Cal-Wood Door | Fire-resistant composite wood structure particularly adapted for use in fire doors |
| US4661398A (en) * | 1984-04-25 | 1987-04-28 | Delphic Research Laboratories, Inc. | Fire-barrier plywood |
| KR100728746B1 (en) * | 2006-05-22 | 2007-06-14 | 성남기업(주) | A uninflammable board and the manufacturing |
| US20090065972A1 (en) * | 2007-07-03 | 2009-03-12 | Feigin Michael E | Method for manufacturing a construction board |
| CN101377086B (en) * | 2007-08-27 | 2011-12-07 | 杨长江 | Environment protection non-brick energy-saving fireproof wall body |
| FR2970010B1 (en) * | 2010-12-30 | 2013-01-04 | Vincent Damour | ACOUSTIC AND / OR THERMAL INSULATION PANEL WITH A MAGNESIUM CEMENT-BASED SOUL |
| CN102503351B (en) * | 2011-10-21 | 2013-06-05 | 仪陇县民信高分子材料科技有限公司 | Glass magnesium fireproof board |
| CN102514322A (en) * | 2011-11-15 | 2012-06-27 | 长春工业大学 | Flame-retardant thermal insulation material and preparation method thereof |
| CN102584168A (en) * | 2012-02-13 | 2012-07-18 | 李国才 | Low-density glass magnesium fire-proof board and preparation method |
-
2014
- 2014-10-10 NZ NZ719711A patent/NZ719711A/en unknown
- 2014-10-10 AU AU2014334513A patent/AU2014334513B2/en active Active
- 2014-10-10 WO PCT/AU2014/050280 patent/WO2015051419A1/en active Application Filing
Also Published As
| Publication number | Publication date |
|---|---|
| WO2015051419A1 (en) | 2015-04-16 |
| AU2014334513B2 (en) | 2018-03-29 |
| AU2014334513A1 (en) | 2016-05-26 |
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