WO2008062289A2 - Method for producing an insulating element for wall or coating and element obtained thereby - Google Patents

Method for producing an insulating element for wall or coating and element obtained thereby Download PDF

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Publication number
WO2008062289A2
WO2008062289A2 PCT/IB2007/003582 IB2007003582W WO2008062289A2 WO 2008062289 A2 WO2008062289 A2 WO 2008062289A2 IB 2007003582 W IB2007003582 W IB 2007003582W WO 2008062289 A2 WO2008062289 A2 WO 2008062289A2
Authority
WO
WIPO (PCT)
Prior art keywords
insulating
previous
fibres
mixing
cement
Prior art date
Application number
PCT/IB2007/003582
Other languages
French (fr)
Other versions
WO2008062289A3 (en
Inventor
Max Canti
Original Assignee
Labicer-Laboratorio Industrial Ceramico, S.A.
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 Labicer-Laboratorio Industrial Ceramico, S.A. filed Critical Labicer-Laboratorio Industrial Ceramico, S.A.
Publication of WO2008062289A2 publication Critical patent/WO2008062289A2/en
Publication of WO2008062289A3 publication Critical patent/WO2008062289A3/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/30—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon
    • B28B1/32—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon by projecting, e.g. spraying
    • 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
    • B28B1/002—Producing shaped prefabricated articles from the material assembled from preformed 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
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • B28B11/042—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers with insulating material
    • 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
    • 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
    • C04B28/06—Aluminous cements
    • C04B28/065—Calcium aluminosulfate cements, e.g. cements hydrating into ettringite
    • 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
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • 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
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • 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
    • C04B2111/00034—Physico-chemical characteristics of the mixtures
    • C04B2111/00146—Sprayable or pumpable mixtures
    • 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
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • 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

Definitions

  • the invention concerns the producing of insulating panels or elements for coatings or for walls having air passages, and in particular it refers to a method for producing an insulating element for wall or for coating and the element obtained thereby.
  • thermo-acoustic insulating properties and infrared barrier function with also the possibility to house electrical nets inside its interspaces fit for luminous devices or loudspeaker, with in view bas-relief or high relief surface, optionally decorated and/or metallized, and the back surface provided with housing for hooking or attaching devices or with said devices housed therein.
  • FIG. 1 shows a schematic view of a formwork, with the forming die, the insulating element made of cement with fibres thixotropic layer, the infrared radiation reflecting element, and provided with spacer heels made of foam polyurethane;
  • FIG. 2 shows a schematic view of the insulating element inside the formwork
  • FIG. 3 shows a schematic view of a cover forming means after the deposit of a cement with fibres thixotropic layer, and housing hooking means of the insulating element and ready for the coupling to the formwork;
  • FIG. 4 shows a schematic view of the formwork containing the forming die housing the insulating element which is subjected to pressure in order to weld the cement with fibres layers in the plastic state matching for mutual penetration.
  • - Figure 5 shows a schematic section view of the formed element of the present invention.
  • FIG. 6 shows a schematic axonometric view of the formed element of the present invention.
  • the method of the present invention provides initially to use a formwork 1, with perimetrical borders which defines the element thickness, and a properly equipped cover 6 thereof.
  • the method further provides to place onto the bottom of the formwork a forming die 2 made of silicone or polyurethane rubber or a stiff die made of resin or metal.
  • a forming die 2 made of silicone or polyurethane rubber or a stiff die made of resin or metal.
  • the formwork bottom may be used for making elements with planar surfaces.
  • the die may be predisposed to house luminous led connected to an electrical net to be housed therein.
  • the method comprises also the step of decorating the die, depositing a layer of coloring oxides, manually with brushes or automatically, depositing with silk screens the oxides powder or with digital aerography, or using digital ink jet systems.
  • the method provides to deposit onto the decorated surface a thixotropic cement with fibres mixing, optionally a mortar comprising inorganic ligand and calcareous and silicon aggregates is deposited, said ligand may be a sulphate-aluminate.
  • the 'CSA' (sulphate-aluminate) mixing derives from a clinker produced by the baking of limestone, bauxite, and dihydrated calcium sulphate.
  • the ligand features are the quick set and hardening for making of ettringite, salt with thick needle-shaped crystals.
  • the mortar formulation is provided to add compounds and additives for enhance the mechanical features of the final hand- manufactured.
  • the compound or additive may be superplasticizers or hyperplasticizers of the acrylic or polycarboxylic type. Also cohesives and reactive filler as bentonite, silica smoke, or natural pozzolans may be use.
  • inorganic fibres as alkaline-resistant glass fibres, or organic fibres made of propylene or natural fibres, may be used.
  • the method of the present invention provides to deposit the mixing onto two shell- shaped forming means which may be a formwork provided with a forming die 2 and a cover 6 provided with the housing for the hooking devices.
  • a first embodiment of the present method provides to distribute the mixing of mortar and fibres onto these two elements using a distribution gun fixed to a plotter for spreading uniformly and regularly.
  • Said gun is provided with a roving cutting system of the fibre which combines uniformly with the spread mortar.
  • the gun is supplied by a proper pump supplied by a continuously operating mixer where it occurs the direct hydration of the dry mixing.
  • a second embodiment of this method provides to prepare the inorganic fibre- reinforced layer depositing the mixing in a container, like a mortarboard, provided with perimetrical borders, by means of an distribution tube.
  • the mixing is self-levelling by vibration.
  • said element When the element has a consistency and an aspect of a morbid clay, said element is extracted by a sucking plane and deposited on a die where by means of an overlapped counter die subjected to pressure the mixing is permeated into the glass mat which, being wet in the plastic state, reinforces the mixing following the possibly very complex shapes of the forming die.
  • an insulating member comprising an aluminium film coupled by thermowelding with fireproof and transparent polyethylene, or simply coupled, provided on both the surfaces with proper spacer heels 5 made of foam propylene, in such a way that it remains hanging and opportunely spaced from the walls in order to reflect the infrared rays.
  • the thixotropic property allows to stratify in plane and then turn upside down the cover in order to join it to the formwork 1 to weld the two shell shaped elements in the plastic state over the perimetrical borders placed to match, subjecting the closed formwork 1 to a proper plate press or rolls press.
  • the hand-manufactured provided with an interspace with infrared rays reflecting device, may be extract and may be subject to the curing in the environment.
  • the method provides to weld them later inserting an insulating member comprising an infrared barrier, levelling perfectly the matching surfaces.
  • the preferably used inorganic ligand is of the sulphate-aluminate type enriched with pure bentonite which extends the setting time, making also the mixing provided with thixotropic property.
  • the inert charge or aggregate introduced in the cement with fibres mixing may be of the light type as porous foam glass which confers, more than the lightness of the two shell-shaped elements made of cement with fibres, thermo-acoustic insulating properties also to the walls fit for the decorative and bearing structure.
  • a variant of the present invention instead of depositing the infrared reflecting element in the formation step, provides to fill the cavity between the cement with fibres shells with a foam porous glass and the inorganic ligand or also other inorganic ligands, or other lightweight ligands as vermiculite, pumice, perlite, foam or melted clay, or prefabricated panels made of foam plastic materials, inorganic or natural organic fibres mats, or fire-proofed cellulose staples spray deposited with inorganic ligands in order to make a thermal insulating sound-adsorbent layer, or a polyurethane or polystyrene foam, which, during the expansion, fills the whole cavity while the formwork is subjected to pressure in the press.
  • the insulating element is used to work as a building cladding, and thus is mounted directly in contact with the wall, and a polyurethane or polystyrene foam is used, the cement with fibres mixing stratification in the formwork cover is avoided, obtaining simply the decorative anterior coating shell-shaped element provided with an insulating layer.
  • the prefabricated insulating elements or the spraying of the recycled cellulose staples layer, or the polyurethane or polystyrene foam in formation, may be inserted in the cavity between the two shell-shaped , separately hardened, formed elements during the welding step, or only in the anterior decorative shell.
  • the insulating element has been provided with a thermo- insulating member and it may be used directly in contact with the wall for the cladding insulation, or as a disposable formwork for the embedding in the reinforced concrete castings, using the housings of the hooking devices 7 in order to place the spacers between the two walls of the disposable formwork which act also as support of the steel reinforced-concrete rod.
  • the shell-shaped portion, or formed element, which constitutes the back of the insulating element will be provided in surface with cavities to house threaded bushes or hooking bolts, or with the same elements embedded in the forming step.
  • Both the elements made with the planar surface and the elements in low-high relief may be decorated, after hardening, with a digital by light solidifying ink jet printing system, further protected with overlapping of paint containing UV protectors, fireproof, highly resistant to the abrasion, not stainable by any agent comprised the concentrate acids.
  • the proposed objects have been obtained, realizing an innovative insulating element for coating, for walls, and for walls having air passages.
  • the obtained insulating element is high resistant, fireproof, lightweight for walls with an high vertical extension, with decorative in view surface for the reproduction of stones and bricks texture or spatial surfaces, or reproduction of natural material like wood, travertine, tuff, provided in the back with housing for hooking devices, or spacer housing for the formation of disposable formwork for embedding, useful also for predispose and support the steel reinforced-concrete rods, already decorated on the forming step because of the embedding of colouring oxides, or successively decorated with ink jet digital printing systems, using by light solidifying inks, protected with overlapping of not stainable fireproof paint, with possible creation of luminous effects by embedding led, electrical nets, or sound devices housing in the cavity.

Abstract

A method for obtaining an insulating element for walls or for coating comprises at least the following steps: - distributing a thixotropic cement with fibres mixing in the plastic state (3), in order to realize at least a layer of said mixing, over at least a forming means (2, 6) obtaining at least a formed element; - associating at least an insulating member to said formed element.

Description

METHOD FOR PRODUCING AN INSULATING ELEMENT FOR WALL OR COATING AND ELEMENT OBTAINED THEREBY
TECHNICAL FIELD
The invention concerns the producing of insulating panels or elements for coatings or for walls having air passages, and in particular it refers to a method for producing an insulating element for wall or for coating and the element obtained thereby.
DISCLOSURE OF THE INVENTION
The element obtained with the method of the present invention has thermo-acoustic insulating properties and infrared barrier function with also the possibility to house electrical nets inside its interspaces fit for luminous devices or loudspeaker, with in view bas-relief or high relief surface, optionally decorated and/or metallized, and the back surface provided with housing for hooking or attaching devices or with said devices housed therein.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following the features of the invention are shown with particular reference to the attached drawing where:
- figure 1 shows a schematic view of a formwork, with the forming die, the insulating element made of cement with fibres thixotropic layer, the infrared radiation reflecting element, and provided with spacer heels made of foam polyurethane;
- figure 2 shows a schematic view of the insulating element inside the formwork;
- figure 3 shows a schematic view of a cover forming means after the deposit of a cement with fibres thixotropic layer, and housing hooking means of the insulating element and ready for the coupling to the formwork;
- Figure 4 shows a schematic view of the formwork containing the forming die housing the insulating element which is subjected to pressure in order to weld the cement with fibres layers in the plastic state matching for mutual penetration. - Figure 5 shows a schematic section view of the formed element of the present invention;
- Figure 6 shows a schematic axonometric view of the formed element of the present invention.
BEST MODE OF CARRYING OUT THE INVENTION
The method of the present invention provides initially to use a formwork 1, with perimetrical borders which defines the element thickness, and a properly equipped cover 6 thereof.
The method further provides to place onto the bottom of the formwork a forming die 2 made of silicone or polyurethane rubber or a stiff die made of resin or metal. Alternatively the formwork bottom may be used for making elements with planar surfaces.
The die may be predisposed to house luminous led connected to an electrical net to be housed therein.
The method comprises also the step of decorating the die, depositing a layer of coloring oxides, manually with brushes or automatically, depositing with silk screens the oxides powder or with digital aerography, or using digital ink jet systems.
The method provides to deposit onto the decorated surface a thixotropic cement with fibres mixing, optionally a mortar comprising inorganic ligand and calcareous and silicon aggregates is deposited, said ligand may be a sulphate-aluminate.
The 'CSA' (sulphate-aluminate) mixing derives from a clinker produced by the baking of limestone, bauxite, and dihydrated calcium sulphate.
The ligand features are the quick set and hardening for making of ettringite, salt with thick needle-shaped crystals.
According to different forming processes, in the mortar formulation is provided to add compounds and additives for enhance the mechanical features of the final hand- manufactured. The compound or additive may be superplasticizers or hyperplasticizers of the acrylic or polycarboxylic type. Also cohesives and reactive filler as bentonite, silica smoke, or natural pozzolans may be use.
For the taction and flexion resistances inorganic fibres, as alkaline-resistant glass fibres, or organic fibres made of propylene or natural fibres, may be used.
The method of the present invention provides to deposit the mixing onto two shell- shaped forming means which may be a formwork provided with a forming die 2 and a cover 6 provided with the housing for the hooking devices.
A first embodiment of the present method, provides to distribute the mixing of mortar and fibres onto these two elements using a distribution gun fixed to a plotter for spreading uniformly and regularly.
Said gun is provided with a roving cutting system of the fibre which combines uniformly with the spread mortar. The gun is supplied by a proper pump supplied by a continuously operating mixer where it occurs the direct hydration of the dry mixing.
In this way a thin layer of inorganic laminated fibre-reinforced, which upsets perfectly and uniformly the forming die 2 and the cover 6 provided with housing for hooking devices, is obtained.
A second embodiment of this method provides to prepare the inorganic fibre- reinforced layer depositing the mixing in a container, like a mortarboard, provided with perimetrical borders, by means of an distribution tube.
The mixing is self-levelling by vibration.
This embodiment further provides to deposit an insulating member comprising a glass fibre mat or roving with soluble size and to distribute thereon a further layer of self- levelling mixing and waiting a first setting thereof
When the element has a consistency and an aspect of a morbid clay, said element is extracted by a sucking plane and deposited on a die where by means of an overlapped counter die subjected to pressure the mixing is permeated into the glass mat which, being wet in the plastic state, reinforces the mixing following the possibly very complex shapes of the forming die.
Concerning the first disclosed embodiment, once deposited the thixotropic and fibres mixing, yet in the plastic state and spread having a thickness of several millimetres, an insulating member comprising an aluminium film coupled by thermowelding with fireproof and transparent polyethylene, or simply coupled, provided on both the surfaces with proper spacer heels 5 made of foam propylene, in such a way that it remains hanging and opportunely spaced from the walls in order to reflect the infrared rays.
Once deposited the thixotropic mixing onto the cover 6 of the formwork 1 provided with housing for the hooking devices 7 for attaching the finished element to the wall, or provided with housing of the devices to be housed in the making of the element, the thixotropic property allows to stratify in plane and then turn upside down the cover in order to join it to the formwork 1 to weld the two shell shaped elements in the plastic state over the perimetrical borders placed to match, subjecting the closed formwork 1 to a proper plate press or rolls press.
Once finished the setting period the hand-manufactured:, provided with an interspace with infrared rays reflecting device, may be extract and may be subject to the curing in the environment.
In the case of the second method embodiment of the present invention, once completed the hardening of the two formed elements without overlapping them at the plastic state, the method provides to weld them later inserting an insulating member comprising an infrared barrier, levelling perfectly the matching surfaces.
The above disclosed procedure of welding the hardened element may be carried out also in the first embodiment of the invention.
The preferably used inorganic ligand is of the sulphate-aluminate type enriched with pure bentonite which extends the setting time, making also the mixing provided with thixotropic property.
Said preferential ligand allows to carry out the extraction from the dies in extremely brief period of time allowing a continuous step working with fast restoring of the formworks. The inert charge or aggregate introduced in the cement with fibres mixing may be of the light type as porous foam glass which confers, more than the lightness of the two shell-shaped elements made of cement with fibres, thermo-acoustic insulating properties also to the walls fit for the decorative and bearing structure.
A variant of the present invention, instead of depositing the infrared reflecting element in the formation step, provides to fill the cavity between the cement with fibres shells with a foam porous glass and the inorganic ligand or also other inorganic ligands, or other lightweight ligands as vermiculite, pumice, perlite, foam or melted clay, or prefabricated panels made of foam plastic materials, inorganic or natural organic fibres mats, or fire-proofed cellulose staples spray deposited with inorganic ligands in order to make a thermal insulating sound-adsorbent layer, or a polyurethane or polystyrene foam, which, during the expansion, fills the whole cavity while the formwork is subjected to pressure in the press.
If the insulating element is used to work as a building cladding, and thus is mounted directly in contact with the wall, and a polyurethane or polystyrene foam is used, the cement with fibres mixing stratification in the formwork cover is avoided, obtaining simply the decorative anterior coating shell-shaped element provided with an insulating layer.
The prefabricated insulating elements, or the spraying of the recycled cellulose staples layer, or the polyurethane or polystyrene foam in formation, may be inserted in the cavity between the two shell-shaped , separately hardened, formed elements during the welding step, or only in the anterior decorative shell.
With said inserting step the insulating element has been provided with a thermo- insulating member and it may be used directly in contact with the wall for the cladding insulation, or as a disposable formwork for the embedding in the reinforced concrete castings, using the housings of the hooking devices 7 in order to place the spacers between the two walls of the disposable formwork which act also as support of the steel reinforced-concrete rod.
During the forming or welding step hardened elements, electrical nets for luminous led or sound devices for "talking walls" may be inserted in the cave portion. The shell-shaped portion, or formed element, which constitutes the back of the insulating element will be provided in surface with cavities to house threaded bushes or hooking bolts, or with the same elements embedded in the forming step.
Both the elements made with the planar surface and the elements in low-high relief, may be decorated, after hardening, with a digital by light solidifying ink jet printing system, further protected with overlapping of paint containing UV protectors, fireproof, highly resistant to the abrasion, not stainable by any agent comprised the concentrate acids.
The proposed objects have been obtained, realizing an innovative insulating element for coating, for walls, and for walls having air passages.
The obtained insulating element is high resistant, fireproof, lightweight for walls with an high vertical extension, with decorative in view surface for the reproduction of stones and bricks texture or spatial surfaces, or reproduction of natural material like wood, travertine, tuff, provided in the back with housing for hooking devices, or spacer housing for the formation of disposable formwork for embedding, useful also for predispose and support the steel reinforced-concrete rods, already decorated on the forming step because of the embedding of colouring oxides, or successively decorated with ink jet digital printing systems, using by light solidifying inks, protected with overlapping of not stainable fireproof paint, with possible creation of luminous effects by embedding led, electrical nets, or sound devices housing in the cavity.

Claims

1) Method for obtaining an insulating element for walls or for coating characterized in that it comprises at least the following steps: - distributing a thixotropic cement with fibres mixing in the plastic state (3), in order to make at least a layer of said mixing, on at least a forming means (2, 6) obtaining at least a formed element; - associating at least an insulating member to said formed element.
2) Method according to claim 1 characterized in spay distributing the cement with fibres mixing until the layer reaches a thickness of several millimetres.
3) Method according to claim 1 or 2 characterized in using an insulating member comprising an infrared radiation reflecting element (4) and/or insulating conglomerate material .
4) Method according to any of the previous claims characterized in using as forming means (2, 6) two shaped dies in order to obtain two formed elements.
5) Method according to claim 4 characterized in joining the two formed elements by mutually matching the correspondent perimetrical edges thereof.
6) Method according to claim 5 characterized in joining the two formed elements by subjecting the correspondent dies to mutual pressure in order to match and co- penetrate the material in the plastic state of the correspondent edges.
7) Method according to claim 5 characterized in joining the two hardened formed elements by welding or gluing the correspondent edges.
8) Method according to claim 6 characterized in placing at least one of the dies (2) into the formwork (1) during the distributing and pressure steps.
9) Method according to claim 1 or 2 characterized in using a forming means provided with lateral containing walls or a mortarboard forming means.
10) Method according to claim 9 characterized in using an insulating member comprising a glass fibre mat or roving with soluble size. 11) Method according to claim 10 characterized in associating the insulating member to the at least a formed element, overlapping thereto.
12) Method according to claim 11 characterized in distributing a thixotropic cement with fibres mixing in the semi-fluid state onto the insulating member.
13) Method according to claim 12 characterized in extracting said insulating element from the forming means in a non completely hardened condition of the formed element and of the layer overlapped onto the insulating member, depositing the insulating element into a formwork and compressing it by means of a counter die.
14) Method according to any of the previous claims characterized in levelling the cement with fibres mixing layers by vibration.
15) Method according to any of the previous claims characterized in spaying onto at least one of the forming means (2, 6), dies, moulds, mortarboards, an inerts mixing and/or sulphate-aluminate mixing and/or synthetic, organic, inorganic or natural fibres before distributing the cement with fibres mixing.
16) Method according to any of the previous claims characterized in preparing at least one of the forming elements (2, 6), dies, moulds or mortarboards, with colouring oxides to be embedded or with inks, in order to decorate the in view portion of the insulating element.
17) Method according to any of the previous claims characterized in using at least one of the forming means (2, 6), dies, mould or mortarboards, shaped to reproduce ornamental bas relief or high relief, as stones or bricks texture or three- dimensional surfaces.
18) Method according to any of the previous claims characterized in using at least one of the forming means (2, 6) provided with cavities in order to partially and detachably house hooking devices (7), in such a way that they are embedded by the cement with fibres mixing.
19) Method according to any of the previous claims characterized in forming shell- shaped insulating element joining the dies by matching the walls to be welded in the plastic state pressing in a press, optionally a continuous press.
20) Method according to any of the previous claims characterized in forming the shell element by hardening separately the two portions and welding them after levelling the matching portions thereof.
21) Method according to claim 3 characterized in using the infrared radiation reflecting element (4) made of an aluminium plate, coupled with transparent, fireproof polystyrene film in order to weld with air balls formations or smooth
22) Method according to any of the previous claims characterized in using an insulating member provided with spacer heels (5) made of foam propylene or honeycombed transparent material on both the surfaces.
23) Method according to any of the previous claims characterized in pouring between the two formed elements a melted state mixing of lightweight, insulating and ligand, organic or inorganic material, as the porous foam glass, vermiculite, pumice, perlite, foam clay, insulating materials also in combination with fibres, as insulating member or in addiction thereto.
24) Method according to any of the previous claims 1-13 characterized in using as insulating member or in addiction thereto a melted state mixing of lightweight, insulating and ligand, organic or inorganic material, as the porous foam glass, vermiculite, pumice, perlite, foam clay, insulating materials also in combination with fibres, in order to provide the element with thermo-acoustic insulating properties.
25) Method according to any of the previous claims characterized in depositing onto the in view portion of the formed element, in the plastic or melted state, fireproofed recycled cellulose staples, sprayed with ligands directly thereto until forming a suitable acoustic insulating layer with further thermal insulating properties or depositing thereon a polyurethane or polystyrene foam by means of a container cover clamped during the foam expansion.
26) Method according to any of the previous claims characterized in using a thixotropic cement with fibres mixing with inorganic ligands, preferably made of sulphate-aluminate cement added with a suitable quantity of pure bentonite, silica smoke, natural pozzolan, in order to confer thixotropic property and to slow down the very fast ligand reaction, and with fluidifying agents, impregnated inerts in order to limit the absorption of hydrating items in order to avoid mechanical strain loss and waist of time in hardening.
27) Method according to any of the previous claims characterized in using a thixotropic cement with fibres mixing containing foam porous glass, opportunely impregnated or not, with silane in advance in order to avoid harmful excess of water.
28) Method according to any of the previous claims characterized in impregnating with silanes the glass fibres and in impregnating the organic natural fibres with resins or salts for fixing onto the cellular walls thereof.
29) Method according to any of the previous claims characterized in obtaining the in view portion of a formed element without the colouring oxide patina deposited onto the die, in order to carry out the decoration on the hardened element by means of digital ink jet printing and successive fireproofed paint protection, provided with UV radiation protection agents, high resistant to abrasion, not stainable by any agent comprised concentrate agents, paint incorporating also metallizing particles.
30) Method according to any of the previous claims characterized in forming the shell- shaped formed element with the thickness predefined by the dimensions of the side wall of the form work and by the cover application.
31) Method according to any of the previous claims characterized in carrying out the direct welding of the two shells in the plastic state, by overlapping the matching walls and pressing them, by means of a press, actuated also in movement on the formwork walls, with or without introducing an infrared rays reflecting element, with or without filling the cavity with a insulating mixing or prefabricated materials.
32) Method according to any of the previous claims characterized in using the obtained elements not coupled and welded.
33) Method according to any of the previous claims characterized in using the thermo- acoustic insulating obtained elements, for direct plugging of the external walls and internal dividers of rooms with predisposition in the hollow portion of channelization for service nets.
34) Method according to any of the previous claims characterized in using lightweight and of non-flammable class (0) thermo-acoustic insulating elements, obtained for naval room dividers and for internal insulation of the naval walls.
35) Method according to any of the previous claims characterized in introducing in the element in forming step devices or electrical net in order to provide the panel or element with luminous effects by means of housing in the element of led, or sound devices in the cavity.
36) Method according to any of the previous claims characterized in using the insulating elements for disposable formworks for embedding, using the same cavities predisposed for the walls hooking devices in order to house the metallic spacers of the disposable formwork walls which serves as a support the steel rods during the concrete casting in order to obtain simultaneously the internal and external coating, insulating and the bearing wall.
37) Method according to any of the previous claims characterized in distributing the cement with fibres mixing by means of a distribution gun fixed to a plotter for spreading uniformly and regularly.
38) Insulating element made by the method of any of the previous claims characterized in comprising at least one formed element made of the cement with fibres mixing associated to an insulating member.
39) Insulating element according to claim 38 characterized in that the insulating member is comprised between two formed elements mutually fixed.
40) Insulating element according to claim 38 or 39 characterized in that the insulating member comprise at least an infrared radiation reflecting element (4) and/or insulating conglomerate material.
41) Insulating element according to claim 40 characterized in that the infrared radiation reflecting element (4) comprises an aluminium IR mirror plate. 42) Insulating element according to claim 41 characterized in that the aluminium reflecting element (4) is covered with transparent, fireproof polystyrene film in order to weld with air balls formations or smooth.
43) Insulating element according to claim 42 characterized in that the insulating member comprises insulating foam coupled with the infrared reflecting element (4) and spacer heels (5) made of foam propylene or honeycombed transparent material on both sides.
44) Element according to any of the previous claims 38-43 characterized in comprising in correspondence of the portion, opposite to the in view side, housings of hooking devices, or the same devices incorporated in the spraying step of the cement with fibres mixing on the die predisposed or for the deposit of the cement with fibres blade.
PCT/IB2007/003582 2006-11-23 2007-11-22 Method for producing an insulating element for wall or coating and element obtained thereby WO2008062289A2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITPS2006A000043 2006-11-23
ITPS20060043 ITPS20060043A1 (en) 2006-11-23 2006-11-23 ELEMENT FOR VENTILATED WALL COVERING, SHELL, WITH INFRARED BARRIER DEVICE STAYED IN THE INTERCAPEDINE OR INTERCHANGEED FILLED WITH THERMO-ACOUSTIC INSULATING MATERIAL. PROCESS AND ELEMENTS OBTAINED

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WO2008062289A2 true WO2008062289A2 (en) 2008-05-29
WO2008062289A3 WO2008062289A3 (en) 2008-08-14

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8403108B2 (en) 2009-06-12 2013-03-26 Precision Fabrics Group, Inc. Acoustically tunable sound absorption articles and methods of making same
US8439161B2 (en) 2009-06-12 2013-05-14 Precision Fabrics Group, Inc. Acoustically tunable sound absorption articles
WO2020124181A1 (en) * 2018-12-17 2020-06-25 Brasil Da Silva Marcelo Prefabricated modules with sandwich metal panels with thermal- and sound-insulating polyurethane and built-in electrical, hydraulic and sewage installations

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4159361A (en) * 1976-01-19 1979-06-26 Morris Schupack Cold formable, reinforced panel structures and methods for producing them
GB1592363A (en) * 1978-01-13 1981-07-08 Tarmac Ltd Manufacture of constructional elements
FR2579650A1 (en) * 1985-04-01 1986-10-03 Publi Laidoun Sprl Panel for covering building facades

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4159361A (en) * 1976-01-19 1979-06-26 Morris Schupack Cold formable, reinforced panel structures and methods for producing them
GB1592363A (en) * 1978-01-13 1981-07-08 Tarmac Ltd Manufacture of constructional elements
FR2579650A1 (en) * 1985-04-01 1986-10-03 Publi Laidoun Sprl Panel for covering building facades

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8403108B2 (en) 2009-06-12 2013-03-26 Precision Fabrics Group, Inc. Acoustically tunable sound absorption articles and methods of making same
US8439161B2 (en) 2009-06-12 2013-05-14 Precision Fabrics Group, Inc. Acoustically tunable sound absorption articles
US8607929B2 (en) 2009-06-12 2013-12-17 Precision Fabrics Group, Inc. Acoustically tunable sound absorption articles and methods of making same
WO2020124181A1 (en) * 2018-12-17 2020-06-25 Brasil Da Silva Marcelo Prefabricated modules with sandwich metal panels with thermal- and sound-insulating polyurethane and built-in electrical, hydraulic and sewage installations

Also Published As

Publication number Publication date
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WO2008062289A3 (en) 2008-08-14

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