WO2010099944A1 - Method of manufacture of a composite concrete article - Google Patents

Method of manufacture of a composite concrete article Download PDF

Info

Publication number
WO2010099944A1
WO2010099944A1 PCT/EP2010/001310 EP2010001310W WO2010099944A1 WO 2010099944 A1 WO2010099944 A1 WO 2010099944A1 EP 2010001310 W EP2010001310 W EP 2010001310W WO 2010099944 A1 WO2010099944 A1 WO 2010099944A1
Authority
WO
WIPO (PCT)
Prior art keywords
base layer
textile
concrete
textile structure
structures
Prior art date
Application number
PCT/EP2010/001310
Other languages
French (fr)
Inventor
Patricia Clare Belford
Ruth Ellen Morrow
Original Assignee
University Of Ulster
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 University Of Ulster filed Critical University Of Ulster
Priority to GB1116600.6A priority Critical patent/GB2482617B/en
Publication of WO2010099944A1 publication Critical patent/WO2010099944A1/en

Links

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
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
    • B28B7/342—Moulds, cores, or mandrels of special material, e.g. destructible materials which are at least partially destroyed, e.g. broken, molten, before demoulding; Moulding surfaces or spaces shaped by, or in, the ground, or sand or soil, whether bound or not; Cores consisting at least mainly of sand or soil, whether bound or not
    • 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
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0092—Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard
    • 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
    • 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
    • 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
    • B28B23/0075—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects for decorative purposes

Definitions

  • This invention relates to a method of manufacture of a composite concrete article, and in particular to a method of manufacture of a concrete article having textile structures integrated into the surface of the concrete to provide a novel aesthetic and/or functional surface finish.
  • Concrete is a commonly utilised as a construction material due to its low cost, ease of prefabrication into desired shapes and strength.
  • concrete structures have a cold, hard and unattractive surface finish with poor acoustic properties.
  • An object of the present invention is to improve the appearance and/or acoustic or other surface properties of concrete by integrating textile structures into concrete articles such that at least a portion of the textile structures define at least a portion of the exposed surfaces of the articles.
  • a method of manufacturing a composite concrete article comprising forming, affixing or applying at least one textile structure onto a base layer, said base layer comprising a soluble substrate, and incorporating the at least one textile structure into a body of wet uncured concrete whereby the base layer dissolves leaving the at least one textile structure embedded in the surface of the concrete, such that the at least one textile structure defines at least a portion of a surface of the cured concrete article.
  • the base layer comprises a water soluble polymeric sheet material.
  • the method may comprise affixing the or each textile structure to the base layer by stitching the textile structure to the base layer or forming the textile structure directly on the base layer such that the base layer acts as a temporary support for the textile structure.
  • the or each textile structure may be affixed to the base layer by means of an adhesive.
  • the textile structure may comprise a pattern of stitching, preferably stitched directly onto the base layer.
  • the textile structure may comprise a woven or lace structure which may be interwoven onto the base layer.
  • a plurality of textile structures, which may comprise a number of different textile structures, may be affixed to or applied to the concrete structure to create different visual and/or textural effects and textures on the surface of the finished product.
  • the method comprises affixing or forming at least one textile structure onto a water soluble base layer and placing the base layer into a mould with the at least one textile structure in contact with a face of the mould, pouring uncured concrete into the mould such that the concrete dissolves the base layer and flows into the at least one textile structure to embed the at least one textile structure into the concrete.
  • the base layer temporarily supports the textile structures until the concrete is poured onto the textile structures, whereupon the base layer dissolves to leave the textile structures intact and in the desired position in the surface of the concrete. Once cured, the concrete itself supports the textile structures.
  • the textile structures are formed from a polymeric thread or yarn, such as polyester thread, nylon or any other suitable alkaline resistant textile material.
  • Figure 1 is a view of a concrete article manufactured in accordance with an embodiment of the present invention.
  • Figure 2 is a view of a further example of a concrete article manufactured in accordance with an embodiment of the present invention.
  • a method of manufacturing a composite concrete article in accordance with an embodiment of the present invention comprises initially forming a textile structure, such as a pattern of stitch work, embroidery, applique or lacework to create a desired pattern or visual or textural effect to be applied to a concrete article, said textile structure being formed on or adhered to a soluble base layer to temporarily support the textile structure.
  • the textile structure may be formed directly onto the base layer, for example by stitching through the base layer.
  • one or more preformed textile structures may be affixed to the base layer, by stitching or by a suitable adhesive, where the textile structure is preformed.
  • Several discrete textile structures of different types may be affixed to, applied to or formed on the base layer to create a desired pattern.
  • the base layer along with the textile structures formed or affixed thereon, is then placed into a mould, with the textile structures face down, and wet uncured concrete is poured into the mould on top of the base layer.
  • the wet concrete causes the water soluble base layer to dissolve while the concrete flows into and penetrates the textile structures such that they become embedded in the surface of the concrete.
  • the base layer acts as a temporary binder for the textile structures to support the textile structures until they become embedded in and supported by the concrete to form a surface pattern or texture in the finished product.
  • a wetter than normal mix of concrete may be used.
  • the finished composite concrete article is removed from the mould.
  • a wide variety of patterns and textures can be integrated into the surface of the concrete, utilising the soluble base layer to support the textile structures until they are applied and embedded into the concrete.
  • the textile structures may be formed from any suitable material provided it is able to withstand the strong alkaline environment of the uncured concrete.
  • One suitable material comprises polyester or nylon thread.
  • FIGS 1 and 2 show two examples of concrete panels manufactured in accordance with the present invention.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Laminated Bodies (AREA)
  • Producing Shaped Articles From Materials (AREA)

Abstract

A method of manufacturing a composite concrete article comprising forming, affixing or applying at least one textile structure onto a base layer, said base layer comprising a soluble substrate, and incorporating the at least one textile structure into a body of wet uncured concrete whereby the base layer dissolves leaving the at least one textile structure embedded in the surface of the concrete, such that the at least one textile structure defines at least a portion of a surface of the cured concrete article.

Description

i
Method of manufacture of a Composite concrete article
This invention relates to a method of manufacture of a composite concrete article, and in particular to a method of manufacture of a concrete article having textile structures integrated into the surface of the concrete to provide a novel aesthetic and/or functional surface finish.
Concrete is a commonly utilised as a construction material due to its low cost, ease of prefabrication into desired shapes and strength. However, concrete structures have a cold, hard and unattractive surface finish with poor acoustic properties.
An object of the present invention is to improve the appearance and/or acoustic or other surface properties of concrete by integrating textile structures into concrete articles such that at least a portion of the textile structures define at least a portion of the exposed surfaces of the articles.
Prior art attempts to adhere textile materials to the surface of concrete articles have mainly been focussed on applying such materials to the surface of the finished concrete articles. Few attempts have been made to integrate textile materials into concrete articles, mainly due to the harsh environment posed by uncured concrete (highly alkaline) and the difficulty in adhering a textile material to the concrete structure in a manner such that the textile material will not simply peel off the concrete once it has set. Where it is desired to embed complex and delicate textile structures into the surface of a concrete product, a problem arises in that the act of pouring concrete onto the textile structures may dislodge or damage the textile structures or subsume the textile structures into the concrete.
According to the present invention there is provided a method of manufacturing a composite concrete article comprising forming, affixing or applying at least one textile structure onto a base layer, said base layer comprising a soluble substrate, and incorporating the at least one textile structure into a body of wet uncured concrete whereby the base layer dissolves leaving the at least one textile structure embedded in the surface of the concrete, such that the at least one textile structure defines at least a portion of a surface of the cured concrete article.
Preferably the base layer comprises a water soluble polymeric sheet material.
The method may comprise affixing the or each textile structure to the base layer by stitching the textile structure to the base layer or forming the textile structure directly on the base layer such that the base layer acts as a temporary support for the textile structure. Alternatively the or each textile structure may be affixed to the base layer by means of an adhesive.
In one embodiment, the textile structure may comprise a pattern of stitching, preferably stitched directly onto the base layer. In an alternative embodiment the textile structure may comprise a woven or lace structure which may be interwoven onto the base layer. A plurality of textile structures, which may comprise a number of different textile structures, may be affixed to or applied to the concrete structure to create different visual and/or textural effects and textures on the surface of the finished product.
In one embodiment the method comprises affixing or forming at least one textile structure onto a water soluble base layer and placing the base layer into a mould with the at least one textile structure in contact with a face of the mould, pouring uncured concrete into the mould such that the concrete dissolves the base layer and flows into the at least one textile structure to embed the at least one textile structure into the concrete. The base layer temporarily supports the textile structures until the concrete is poured onto the textile structures, whereupon the base layer dissolves to leave the textile structures intact and in the desired position in the surface of the concrete. Once cured, the concrete itself supports the textile structures.
Preferably the textile structures are formed from a polymeric thread or yarn, such as polyester thread, nylon or any other suitable alkaline resistant textile material.
An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:-
Figure 1 is a view of a concrete article manufactured in accordance with an embodiment of the present invention; and
Figure 2 is a view of a further example of a concrete article manufactured in accordance with an embodiment of the present invention.
A method of manufacturing a composite concrete article in accordance with an embodiment of the present invention comprises initially forming a textile structure, such as a pattern of stitch work, embroidery, applique or lacework to create a desired pattern or visual or textural effect to be applied to a concrete article, said textile structure being formed on or adhered to a soluble base layer to temporarily support the textile structure. The textile structure may be formed directly onto the base layer, for example by stitching through the base layer. Alternatively one or more preformed textile structures may be affixed to the base layer, by stitching or by a suitable adhesive, where the textile structure is preformed. Several discrete textile structures of different types may be affixed to, applied to or formed on the base layer to create a desired pattern.
The base layer, along with the textile structures formed or affixed thereon, is then placed into a mould, with the textile structures face down, and wet uncured concrete is poured into the mould on top of the base layer. The wet concrete causes the water soluble base layer to dissolve while the concrete flows into and penetrates the textile structures such that they become embedded in the surface of the concrete. Thus the base layer acts as a temporary binder for the textile structures to support the textile structures until they become embedded in and supported by the concrete to form a surface pattern or texture in the finished product. A wetter than normal mix of concrete may be used.
Once cured, the finished composite concrete article is removed from the mould.
A wide variety of patterns and textures can be integrated into the surface of the concrete, utilising the soluble base layer to support the textile structures until they are applied and embedded into the concrete.
The textile structures may be formed from any suitable material provided it is able to withstand the strong alkaline environment of the uncured concrete. One suitable material comprises polyester or nylon thread.
Figures 1 and 2 show two examples of concrete panels manufactured in accordance with the present invention.
The invention is not limited to the embodiment(s) described herein but can be amended or modified without departing from the scope of the present invention.

Claims

Claims
1. A method of manufacturing a composite concrete article comprising forming, affixing or applying at least one textile structure onto a base layer, said base layer comprising a soluble substrate, and incorporating the at least one textile structure into a body of wet uncured concrete whereby the base layer dissolves leaving the at least one textile structure embedded in the surface of the concrete, such that the at least one textile structure defines at least a portion of a surface of the cured concrete article.
2. A method as claimed in claim 1 , wherein the base layer comprises a water soluble polymeric sheet material.
3. A method as claimed in claim 1 or claim 2, wherein the method comprises affixing at least one or said one or more textile structures to the base layer by stitching the textile structure to the base layer or forming the textile structure directly on the base layer such that the base layer acts as a temporary support for the textile structure.
3. A method as claimed in any preceding claim, wherein at least one or said one or more textile structures is affixed to the base layer by means of an adhesive.
4. A method at claimed in any preceding claim, wherein at least one of said one or more textile structures comprises a pattern of stitching stitched directly onto the base layer.
5. A method as claimed in any preceding claim wherein at least one said one or more textile structures comprises a woven or lace structure which may be interwoven onto the base layer.
6. A method as claimed in any preceding claim, wherein a plurality of textile structures, comprising a number of different, similar or identical textile structures, are affixed to or applied to the concrete structure to create different visual and/or textural effects and textures on the surface of the finished product.
7. A method as claimed in any preceding claim, wherein the method comprises affixing or forming at least one textile structure onto a water soluble base layer and placing the base layer into a mould with the at least one textile structure in contact with a face of the mould, pouring uncured concrete into the mould such that the concrete dissolves the base layer and flows into the at least one textile structure to embed the at least one textile structure into the concrete.
8. A method as claimed in claim 8, wherein the base layer temporarily supports the at least one textile structure until the concrete is poured onto the textile structure, whereupon the base layer dissolves to leave the at least one textile structure intact and in the desired position in the surface of the concrete, such that, once cured, the concrete itself supports the at least one textile structure.
9. A method as claimed in any preceding claim, at least one of said one or more textile structures is formed from a polymeric thread or yarn, such as polyester thread, nylon or any other suitable alkaline resistant textile material.
PCT/EP2010/001310 2009-03-04 2010-03-03 Method of manufacture of a composite concrete article WO2010099944A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB1116600.6A GB2482617B (en) 2009-03-04 2010-03-03 Method of manufacture of a composite concrete article

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0903684.9 2009-03-04
GBGB0903684.9A GB0903684D0 (en) 2009-03-04 2009-03-04 Method of manufacture of a composite concrete article

Publications (1)

Publication Number Publication Date
WO2010099944A1 true WO2010099944A1 (en) 2010-09-10

Family

ID=40580580

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2010/001310 WO2010099944A1 (en) 2009-03-04 2010-03-03 Method of manufacture of a composite concrete article

Country Status (2)

Country Link
GB (2) GB0903684D0 (en)
WO (1) WO2010099944A1 (en)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB490667A (en) * 1936-12-18 1938-08-18 Victor Lefebure Composite board material and its manufacture
US2506244A (en) * 1945-06-28 1950-05-02 Spolek Pro Chemickou A Lutni V Method of producing ceramic bodies having longitudinal passages
DE3622573A1 (en) * 1986-07-04 1988-01-07 Hoechst Ag Process for producing a thin-walled ceramic component
WO2002072328A1 (en) * 2001-03-07 2002-09-19 Advanced Ceramics Research, Inc. Water soluble tooling materials for composite structures

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB490667A (en) * 1936-12-18 1938-08-18 Victor Lefebure Composite board material and its manufacture
US2506244A (en) * 1945-06-28 1950-05-02 Spolek Pro Chemickou A Lutni V Method of producing ceramic bodies having longitudinal passages
DE3622573A1 (en) * 1986-07-04 1988-01-07 Hoechst Ag Process for producing a thin-walled ceramic component
WO2002072328A1 (en) * 2001-03-07 2002-09-19 Advanced Ceramics Research, Inc. Water soluble tooling materials for composite structures

Also Published As

Publication number Publication date
GB2482617B (en) 2012-09-19
GB2482617A (en) 2012-02-08
GB0903684D0 (en) 2009-04-15
GB201116600D0 (en) 2011-11-09

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