WO2000000449A1 - Materiau composite - Google Patents

Materiau composite Download PDF

Info

Publication number
WO2000000449A1
WO2000000449A1 PCT/SG1998/000048 SG9800048W WO0000449A1 WO 2000000449 A1 WO2000000449 A1 WO 2000000449A1 SG 9800048 W SG9800048 W SG 9800048W WO 0000449 A1 WO0000449 A1 WO 0000449A1
Authority
WO
WIPO (PCT)
Prior art keywords
composite material
mixture
reinforcing fibres
material according
final mixture
Prior art date
Application number
PCT/SG1998/000048
Other languages
English (en)
Inventor
Loun Cheong Yip
Original Assignee
Loun Cheong Yip
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Loun Cheong Yip filed Critical Loun Cheong Yip
Priority to AU82520/98A priority Critical patent/AU8252098A/en
Priority to PCT/SG1998/000048 priority patent/WO2000000449A1/fr
Publication of WO2000000449A1 publication Critical patent/WO2000000449A1/fr

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—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 hydraulic cements other than calcium sulfates
    • 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
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/38—Fibrous materials; Whiskers
    • C04B14/42—Glass
    • 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
    • C04B16/00—Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B16/04—Macromolecular compounds
    • C04B16/06—Macromolecular compounds fibrous
    • C04B16/0616—Macromolecular compounds fibrous from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B16/065—Polyacrylates; Polymethacrylates
    • C04B16/0658—Polyacrylonitrile
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00241—Physical properties of the materials not provided for elsewhere in C04B2111/00
    • C04B2111/00318—Materials characterised by relatively small dimensions, e.g. small thickness
    • 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
    • C04B2111/80—Optical properties, e.g. transparency or reflexibility
    • C04B2111/802—White cement

Definitions

  • the invention relates to a composite material and especially, a composite material suitable for molding into a panel.
  • Synthetic panels are known which are used in place of wood panels, for example, for external panelling and internal partitions in buildings. These conventional synthetic panels include cement boards, gypsum boards, calcium silicate boards, phenolic boards etc.
  • a composite material comprises cement and reinforcing fibres, the reinforcing fibres being separated into filaments and having a length less than 10mm.
  • a method of manufacturing a composite material comprises forming a first mixture comprising water and cement; adding reinforcing fibres and a surfactant to the first mixture to form a final mixture; generating foaming of the final mixture; introducing the final mixture into a mold; permitting the final mixture to harden within the mold; and subsequently removing the hardened composite material from the mold.
  • An advantage of the invention is that the use of a surfactant separates the reinforcing fibres into finer filaments which promotes increased strength of the composite material.
  • the reinforcing fibres in the second aspect of the invention may be less than 10mm.
  • the reinforcing fibres have a length of 5mm to 9mm and preferably, a length of 6mm.
  • the composite material may further comprise an inorganic filler.
  • the first mixture further comprises an inorganic filler.
  • the inorganic filler comprises a clay, which typically comprises kaolin clay.
  • the reinforcing fibres comprise glass fibres and/or polyacrylonitrile fibres.
  • the cement comprises white cement.
  • the cement may be portland cement.
  • White cement has the advantage that colouring may be added to the mixture to colour the composite material more easily than other cements.
  • Portland cement has the advantage that it is less expensive than white cement.
  • the method further comprises the step of adding a cure accelerator before the final mixture is introduced into the mold.
  • a cure accelerator aids hardening of the composite material.
  • the cure accelerator is added to the final mixture during foaming of the final mixture and prior to introducing the mixture into the mold.
  • the cure accelerator may comprise calcium chloride.
  • the composite product may comprise additives, such as plasticises and cement strengtheners .
  • the method may further comprises adding other ingredients, such as, plasticises, flow promoters and cement strengtheners.
  • the method further comprises mixing together the reinforcing fibres, the surfactant and water to form a second mixture and subsequently mixing the first and the second mixtures together to form the final mixture.
  • the surfactant comprises a non-ionic surfactant, such as an ethoxylated phenol.
  • suitable surfactants may be Empilan NP 9 or Empilan NP 6 as manufactured by Albright & Wilson.
  • the composite material is moulded into a substantially planar panel and, typically, the mold is orientated such that the planar surfaces of the panel are substantially horizontal during hardening.
  • the mold may be orientated such that the planar surfaces of the panel are substantially vertical during hardening.
  • the composite material may be laminated to increase the shear strength of the composite material.
  • Typical laminating materials may include plastics, veneers, thin metal sheets or any other suitable materials.
  • the non-ionic ethoxylated phenol surfactants comprised a mixture of Empilan NP 9 and Empilan NP 6 as manufactured by Albright & Wilson.
  • the action of the surfactant on the fibres is to cause the fibres to separate into filaments and disperse as filaments within the fibre/surfactant mixture.
  • About 2.5kg of water can be added to assist dispersion and mixing.
  • 35kg of white cement was then mixed with 5kg of kaolin clay and about 20kg of water.
  • the fibre and surfactant mixture is added to the cement, clay and water mixture and the resulting mixture homogenised with a multiblade high speed disperser.
  • the resulting mixture foams and air is entrained within the mixture.
  • the degree of forming of the mixture can be controlled. For example, a surfactant having a high ethoxylation will generate more forming and therefore produce a product with a relatively lower density. A surfactant with a low ethoxylation will generate less forming and therefore produce a product with a relatively high density.
  • An example of a non-ionic ethoxylated phenol surfactant with a high ethoxylation is Empilan NP9 and an example of a non- ironic ethoxylated phenol surfactant having a low ethoxylation is Empilan NP6.
  • densities in between can be achieved by mixing appropriate ratios of Empilan NP 6 with Empilan NP 9 to achieve the desired density.
  • the mixture While the mixture is undergoing foaming, cure accelerations, flow promoters and cement strengtheners are added. When a suitable degree of foaming is achieved the mixture is poured into molds.
  • the molds are horizontal open cast molds with the depth of the mold ranging from 8mm to approximately 30mm with a length of approximately 2.4m and a width of approximately 1.2m.
  • patterns can be formed in the surface of the mold to mold a textured surface on one side of the cured product. Marbelising effects may be produced by the addition of colouring or dies to the mixture just prior to pouring of the mixture into the molds.
  • the molds be orientated vertically such that the opening of the mold through which the mixture is introduced defines an edge of the cured product.
  • the mixture is left to cure in a thermally insulated environment until it has hardened which may be, for example, 12 to 48 hours.
  • the composite material is then removed from the mold.
  • the composite material was found to have good thermal insulation, sound insulation and fire resistant property.
  • the composite material was also found to have good dimensional stability in humid and temperature fluctuating conditions. Under water immersion conditions the composite material was found to take up 50% of its weight in water but with a negligible change in external dimensions. The absorbed water was then released under drying out conditions . In addition, the composite material has an alkaline surface pH of approximately 12. Therefore, being inorganic and alkaline, the composite material resists attack by insects and organisms and has resistance to mold growth. In addition, the composite material has no toxic vapour emission during service.
  • the composite material was found to be workable in a similar manner to wood and may be sawn, drilled, screwed and air stapled with standard wood working tools.
  • the composite material is particularly suitable for use in the form of a board or panel.
  • the composite material may be laminated to increase the strength of the board or panel.
  • Typical laminates include plastics, veneers, thin metal sheets, conventional high pressure laminates and melamine films.
  • the finished board or panel may be used as raised flooring, wall panels, ceiling panels, fire partitions or for other construction uses.
  • the required density of the composite material may be varied by choosing the surfactant or mixture of surfactants, water and time appropriately to control the foaming during mixing.
  • Other applications of the composite material include a substitute for ceramic tiles, fatias, wall cladding and linings, partitions, dry walls, ceiling panels, toilet and shower cubicles, fire and/or sound insulating partitions.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Civil Engineering (AREA)
  • Laminated Bodies (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

La présente invention concerne un matériau composite constitué, de ciment, d'un matériau de charge inorganique et de fibres structurantes. Pendant la fabrication, un tensioactif dissocie les filaments des fibres structurantes. La longueur des fibres n'excède pas 10 mm.
PCT/SG1998/000048 1998-06-26 1998-06-26 Materiau composite WO2000000449A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
AU82520/98A AU8252098A (en) 1998-06-26 1998-06-26 A composite material
PCT/SG1998/000048 WO2000000449A1 (fr) 1998-06-26 1998-06-26 Materiau composite

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/SG1998/000048 WO2000000449A1 (fr) 1998-06-26 1998-06-26 Materiau composite

Publications (1)

Publication Number Publication Date
WO2000000449A1 true WO2000000449A1 (fr) 2000-01-06

Family

ID=20429864

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/SG1998/000048 WO2000000449A1 (fr) 1998-06-26 1998-06-26 Materiau composite

Country Status (2)

Country Link
AU (1) AU8252098A (fr)
WO (1) WO2000000449A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1553065A3 (fr) * 2004-01-07 2006-03-22 Schotter- und Betonwerk Karl SCHWARZL Betriebsgesellschaft m.b.H. Béton frais et béton durci, méthode pour sa fabrication et utilisation du béton durci
US8147610B2 (en) 2007-10-02 2012-04-03 James Hardie Technology Limited Cementitious formulations and products
US8993462B2 (en) 2006-04-12 2015-03-31 James Hardie Technology Limited Surface sealed reinforced building element

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2148871A (en) * 1983-10-31 1985-06-05 Pilkington Brothers Plc Sheet material of fibre-reinforced cement
EP0120800B1 (fr) * 1983-03-28 1988-01-13 "Société des Anciens Etablissements LOUDE Fréres" Société Anonyme dite: Composition durcissable, procédé de mise en oeuvre de celle-ci et application notamment au colmatage d'orifices
EP0333299A1 (fr) * 1988-03-18 1989-09-20 Hollandsche Beton Groep N.V. Procédé pour la fabrication d'une composition à utiliser pour revêtements routiers

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0120800B1 (fr) * 1983-03-28 1988-01-13 "Société des Anciens Etablissements LOUDE Fréres" Société Anonyme dite: Composition durcissable, procédé de mise en oeuvre de celle-ci et application notamment au colmatage d'orifices
GB2148871A (en) * 1983-10-31 1985-06-05 Pilkington Brothers Plc Sheet material of fibre-reinforced cement
EP0333299A1 (fr) * 1988-03-18 1989-09-20 Hollandsche Beton Groep N.V. Procédé pour la fabrication d'une composition à utiliser pour revêtements routiers

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1553065A3 (fr) * 2004-01-07 2006-03-22 Schotter- und Betonwerk Karl SCHWARZL Betriebsgesellschaft m.b.H. Béton frais et béton durci, méthode pour sa fabrication et utilisation du béton durci
US8993462B2 (en) 2006-04-12 2015-03-31 James Hardie Technology Limited Surface sealed reinforced building element
US8147610B2 (en) 2007-10-02 2012-04-03 James Hardie Technology Limited Cementitious formulations and products
US8574360B2 (en) 2007-10-02 2013-11-05 James Hardie Technology Limited Cementitious formulations and products

Also Published As

Publication number Publication date
AU8252098A (en) 2000-01-17

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