WO2013080025A4 - Building composite panel and manufacturing method thereof - Google Patents

Building composite panel and manufacturing method thereof Download PDF

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Publication number
WO2013080025A4
WO2013080025A4 PCT/IB2012/002555 IB2012002555W WO2013080025A4 WO 2013080025 A4 WO2013080025 A4 WO 2013080025A4 IB 2012002555 W IB2012002555 W IB 2012002555W WO 2013080025 A4 WO2013080025 A4 WO 2013080025A4
Authority
WO
WIPO (PCT)
Prior art keywords
composition
panel
inner core
composite panel
weight
Prior art date
Application number
PCT/IB2012/002555
Other languages
French (fr)
Other versions
WO2013080025A1 (en
Inventor
Andrea FONTANA DONATELLI
Original Assignee
E-Comfort S.A.S. Di Fontana Donatelli Andrea & C.
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 E-Comfort S.A.S. Di Fontana Donatelli Andrea & C. filed Critical E-Comfort S.A.S. Di Fontana Donatelli Andrea & C.
Publication of WO2013080025A1 publication Critical patent/WO2013080025A1/en
Publication of WO2013080025A4 publication Critical patent/WO2013080025A4/en

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
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/18—Waste materials; Refuse organic
    • C04B18/24—Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper, cork
    • C04B18/28—Mineralising; Compositions therefor
    • 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
    • C04B28/001—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 unburned clay
    • 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
    • C04B28/04—Portland cements
    • 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
    • C04B28/24—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 alkyl, ammonium or metal silicates; containing silica sols
    • C04B28/26—Silicates of the alkali metals
    • 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
    • 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
    • C04B2111/52—Sound-insulating materials
    • 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 building composite panel is disclosed, adapted to be supported by a fixed structure and manufactured entirely by a cold operation, comprising an inner core of mineralized wood fibers, a first coating formed by a first fluid composition comprising a solution of crude clay in water, adapted to impregnate said mineralized wood fibers and naturally dried, and a second outer coating formed by a second thick composition comprising a mixture of binders and clay in water and again undergoing a natural drying operation. A method of manufacturing such a panel is also disclosed.

Claims

AMENDED CLAIMS received by the International Bureau on 3 June 2013 (03.06.2013).
1. A building composite panel, adapted to be supported by a fixed structure, comprising an inner core of mineralized wood fibers, a first coating layer formed by a first composition comprising a solution of crude clay impregnating said mineralized wood fibers, and a second outer coating layer formed by a second hardening composition comprising a mixture of binders and clay.
2. The composite panel of claim 1, wherein the first composition comprises a solution containing preferably 35% to 40% by weight of water and 60% to 65% by weight of clay adapted to penetrate in the interstices of the mineralized wood fibers.
3. The composite panel of claim 2, wherein the said clay is selected from the group comprising kaolins, illites and earthenware .
4. The composite panel of claim 1, wherein the mixture constituting the second composition contains preferably 30% to 35% by weight of water, 13% to 14% by weight of potassium or sodium silicate as a binder, 25% to 30% by weight of clay and 25% to 30% by weight of kaolin.
5. The composite panel of claim 4, wherein the sodium or potassium silicate used as a binder in the second composition, is replaced entirely or partially by other silicates or carbonates, preferably calcium carbonate.
6. The composite panel of claim 4 or 5, wherein 5-7% by- weight of inerts such as chamotte or siliceous sand is added to the binder.
7. The composite panel of preceding claims, wherein the total amount of clay contained in the first and second coating composition, is equal to at least 70% of the overall weight of the dry compositions.
8. A method of manufacturing a composite panel according to the preceding claims without using thermal treatments, comprising the following steps:
a. preparing the inner core of mineralized wood fibers ;
b. applying on said inner core the first composition impregnat ng the fibers and forming a first coating layer;
c. drying at room temperature the so impregnated and coated inner core;
d. applying the second hardening composition forming a second layer of external coating; and
e. drying at room temperature to complete the finished panel .
9. The method of claim 8, wherein the wood fibers are mineralized with Portland cement.
10. The method of claim 8, wherein the wood fibers are mineralized with magnesite.
11. The method of claim 8, wherein the application of the first composition is carried out by dipping the inner core into said composition.
12. The method of claim 8, wherein the application of the first composition is carried out by injection into the inner core .
13. The method of claim 8, wherein the application of the first composition is carried out by casting or pressing on the inner core .

STATEMENT UNDER ARTICLE 19 (1 )

The amended claims under Article 19 PCT are now directed to the technical features of the product (Claims 1-7) and to its manufacturing method (Claims 8-13).

The composite panel of the present invention is a multilayered product, comprising an inner core, a first coating layer covering and impregnating the inner core and a second outer coating layer making a hard envelope of the panel.

Documents BE 464181 and GB 551701 disclose building panels comprising a mixture of materials which is blended, cast into moulds and then baked at high temperatures of 1 10°C and 150°C respectively. Therefore hardening of the panel is obtained by thermal transformation of the ingredients. These documents neither disclose a multilayered panel nor a panel where hardening or petrification is obtained by natural chemical transformation of the ingredients at room temperature. Even if some of the ingredients may be of the same nature, percentages of the ingredients, physical structure of the panel and its manufacturing method are totally different, and the production of the innovative panel of the present invention moreover is more economical, and environment friendly, since it does not require the expensive and polluting baking process.

PCT/IB2012/002555 2011-12-01 2012-11-26 Building composite panel and manufacturing method thereof WO2013080025A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITMI2011A002197 2011-12-01
IT002197A ITMI20112197A1 (en) 2011-12-01 2011-12-01 CLAY PANEL AND WOOD FIBER

Publications (2)

Publication Number Publication Date
WO2013080025A1 WO2013080025A1 (en) 2013-06-06
WO2013080025A4 true WO2013080025A4 (en) 2013-08-01

Family

ID=45370624

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2012/002555 WO2013080025A1 (en) 2011-12-01 2012-11-26 Building composite panel and manufacturing method thereof

Country Status (2)

Country Link
IT (1) ITMI20112197A1 (en)
WO (1) WO2013080025A1 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20180079691A1 (en) * 2016-09-20 2018-03-22 Usg Interiors, Llc Silicate coating for improved acoustical panel performance and methods of making same
US11753550B2 (en) 2018-06-14 2023-09-12 Usg Interiors, Llc Borate and silicate coating for improved acoustical panel performance and methods of making same

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
BE464181A (en) *
GB551701A (en) * 1941-09-02 1943-03-05 James Bennie Improvements in or relating to the manufacture of wall-boards or slabs
US3549485A (en) * 1968-03-04 1970-12-22 Armstrong Cork Co Flocculation-deflocculation steps in mineral wool-clay board formation
JP2001026475A (en) * 1999-06-17 2001-01-30 Adobakku Internatl Corp Sound insulating material
US6335089B1 (en) * 1999-08-02 2002-01-01 Pacific Bentonite Ltd. Fibre-clay panel

Also Published As

Publication number Publication date
WO2013080025A1 (en) 2013-06-06
ITMI20112197A1 (en) 2013-06-02

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