AU2005200282A1

AU2005200282A1 - A Material for Building or Other Purposes

Info

Publication number: AU2005200282A1
Application number: AU2005200282A
Authority: AU
Inventors: Gerard Kluger
Original assignee: LIQUID PLASTICS CO Pty Ltd
Current assignee: Kluger Gerard F
Priority date: 2004-02-13
Filing date: 2005-01-24
Publication date: 2005-09-01
Anticipated expiration: 2025-01-24
Also published as: AU2005200282B2

Description

AUSTRALIA

Patents Act 1990 Liquid Plastics Co. Pty. Ltd.

COMPLETE SPECIFICATION Invention Title.

A Materialfor Building or Other Purposes The invention is described in the following statement: m:\specifications\500000\503000\503141 cap final dcc.doc SA Material for Building or Other Purposes Field of the Invention This invention relates to a material that may be used as a building material, in construction, in furniture manufacture, as a cladding, as a core for a panel structure, as 0C, a wall or ceiling structure or for other purposes. The invention has particular O application as a material that can be used, with appropriate facings, as a panel for building, construction or other purposes and which exhibits thermal and acoustic Sinsulation or absorption properties.

C 10 The material of this invention has many applications and may be used in many forms including in pre-formed sheet or panel form, either with or without a facing on one or both surfaces of the pre-formed sheet or panel. For the purposes of clarity, the invention will be described herein in relation to its preferred use as a core material for the manufacture of panels or the like where panel has a facing of a suitable facing material such as metal, timber, paper, plaster or any other suitable sheet facing. It will be understood, however, that the invention has broader application and is not limited to its use as a core for panels or other structures.

Background of the Invention Panels of numerous different forms are in current use for structural purposes, as facings, as partitioning, as linings for walls and ceilings, as construction material of all types and for acoustic and thermal insulation purposes in walls and ceilings. Panels currently used for these and similar applications are made of a wide variety of materials and construction techniques. Thus, some panels are formed with a solid core, such as plaster, faced with a cardboard or paper facing material to form plasterboard, while some panels use a light weight core made from, for example, a foamed synthetic plastics material, such as polystyrene, faced on either side with a paper facing material or a more rigid facing material such as timber ply, plasterboard, metal or the like.

Other panel materials are formed using a honeycomb structure core with appropriate facing materials of timber or the like. Panels have been formed as hollow structures and using a variety of in-fill materials Many panels used in the construction, office fit-out and partitioning industries are required to have thermal and/or acoustic insulation properties. Heretofor, many such panels have utilised polystyrene and similar foamed plastics material as a core material notwithstanding that such materials, when subjected to extreme heat, may be inflammable and/or give off toxic smoke or residue. Consequently, such panels are no longer acceptable for many applications.

It is known to use rock wool and fibreglass materials as a core in an insulating panel structure. However, as rock wool has no intrinsic structural strength, any such 0panel structure utilising rock wool as a core insulating material must have relatively rigid structural members to form the panel. Further, rock wool filling or core material N is relatively difficult to handle. Consequently, such panels are relatively uneconomic and are not as efficient in use as corresponding panels formed of polystyrene and N 10 similar materials.

Panels have been proposed to be formed with a core of a light weight, foamed or aerated concrete or concrete-like material. While such panels may have certain structural applications, the thermal and acoustic properties are not as effective as is desired in most applications without forming the panel of an undesirable thickness.

It is therefore desirable to provide an improved material that may be used in the manufacture of a panel structure which material is economical to manufacture and which exhibits excellent thermal and/or acoustic insulation properties.

It is also desirable to provide an improved material particularly for use in the manufacture of a panel structure whereby the panel structure may be used as a facing, as a structural member, as a partition or in many other applications, including cabinet and other furniture uses.

It is also desirable to provide an improved building material that is fire resistant and that, therefore, may be used in fire wall and fire door structures, wall cladding, ceilings and other applications where fire resistance is required.

It is also desirable to provide an improved building material that is substantially non-absorbent.

It is also desirable to provide an improved building material, particularly suitable for use in the manufacture of a panel structure, which is of relatively light weight and which is easy and safe to handle.

It is also desirable to provide an improved building material that is sound absorbent.

It is also desirable to provide an improved panel or building material that has excellent sound insulation properties.

Summary of the Invention In accordance with one aspect of the invention there is provided a building material particularly suitable for use in the manufacture of a panel, said material being formed of foam glass granulate and a granulate binder that binds the granulate together to form a substantially rigid body.

In accordance with another aspect of the invention there is provided a panel comprising a core formed of foam glass granulate and a granulate binder that binds the N granulate together to form a substantially rigid body, and a facing on at least one side of Sthe body, the facing being adhered thereto.

IN 10 The foam glass granulate material may be formed of any suitable particle size, such as ranging from 100 microns to several millimetres, or more, for example up to about 7 millimetres.

Preferably, the foam glass granulate is a blown-glass product, more preferably made from recycled glass. Such material is a mineral product and, as such, is noncombustible. It is not susceptible to biological attack and is highly resistant to acids, organic solvents and other chemicals.

Preferably, the bulk density of the foam glass granulate is less than 200 gram per litre, and it is dimensionally stable up to relatively high temperatures, such as at least about 900 0 C, or more.

Because the building material is formed of glass, it is non-toxic and can be readily recycled.

In one method of producing the building material of the invention, foam glass granulate material is mixed with a binder to bind the individual particles, the mixed foam glass granulate material with binder being formed or moulded to a desired shape or form, such as a planar sheet of predetermined thickness. The binder may comprises an organic or inorganic resin, such as sodium silicate. Preferably, the binder will cure in the atmosphere, although the curing time may be regulated by temperature, depending on the particular binder used. The binder will preferably fuse with the glass granulate to produce a panel-like sheet structure which is dimensionally stable, and is totally non-combustible at fire temperatures. In one preferred form of the invention, the sheet so formed will be laminated with facings on each side which are secured to the core by a suitable adhesive. In another embodiment, the resin binder and granulate material is contained, before curing, between the facing material, and is cured so that the facing material is adhered to the core using the binder resin as the adhesive. In other embodiments, only one facing will be adhered to the material on one side thereof.

In another embodiment, a phenolic resin is used as the binder. It has been found in tests that this binder results in a product which is as fire resistant as the product made N 5 with sodium silicate, and any panel so formed will have a similar fire rating as one 0formed using an organic or inorganic binder resin.

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In another embodiment of the invention, the binder may be foamed within the (material whereby the binder resin fills all voids between the foam glass granulate 0 particles and thereby provides substantially increased insulation properties.

N 10 According to another aspect of the invention there is provided a method of forming a building material, particularly one suitable for use in an insulating panel, comprising the steps of selecting an amount of foam glass granulate of predetermined size range to form the material, mixing the selected granulate with a resin binder, forming a layer of said mixture of predetermined thickness, and curing the resin binder.

According to another aspect of the invention there is provided a method of forming an insulating panel comprising the steps of selecting an amount of foam glass granulate of predetermined size range to form the panel, mixing the selected granulate with a resin binder, forming a layer of said mixture of predetermined thickness, curing the resin binder, and adhering facing material to the opposed surfaces of the formed core.

The particle size of the foam glass granulate used for the core is selected in accordance with the desired end use of the panel. Thus, a relatively large particle size, of, for example, between 2 and 6mm is useful for the construction of a panel used for structural and constructional purposes. Where fire resistance and/or thermal insulation properties are paramount, a foamed resin binder may be used to fill the voids between the relatively large particles.

For a ceiling panel or a decorative panel to be used for acoustic and/or thermal insulation and/or for decorative purposes, a relatively thin panel may be formed using foam glass granulate particles of a size ranging from, for example, 100 microns to 2mm.

When used as a cladding material in or on a building or other structure, the outermost surface may be painted, bagged, rendered or otherwise treated as desired for aesthetic or other purposes.

SBrief Description of the Drawings C In order that the invention is more readily understood, embodiments thereof will now be described with reference to the accompanying drawings: Figure 1 is a perspective view of a panel formed in accordance with one embodiment of the invention; 00 Figure 2 is an enlarged end view of the panel of Figure 1, and O Figure 3 is a perspective view of a panel formed in accordance with a further C embodiment of the invention.

C 10 Description of Preferred Embodiments of the Invention In the embodiment illustrated in Figs. 1 and 2, a panel 12 is formed of a core 14 and facing sheets 16 and 17 on each side of the core 14.

The facing sheets 16 and 17 may be made of any suitable material dependent on the use for which the panel is made. Thus, the facing sheets 16 and 17 may be metal, timber, such as a relatively thin ply veneer, 3 or 5 ply timber sheets, plaster board, cardboard, paper, any form of laminate including plastic laminates, fibreglass, carbon fibre, synthetic plastics material, glass sheet, woven or knitted fabric including fabric made from natural and/or artificial fibres such as cotton, linen, wool, polyester, nylon, canvas and the like, or any other suitable form of facing. It will be apparent that the facing material will be selected in accordance with the use for which the panel is manufactured.

The core 14 of the panel 12 is formed of a plurality of foam glass granulate particles 18 which are selected to be within a predetermined size range. The size range will depend on the panel structure, its intended thickness and use. For a panel to be formed for structural or constructional uses, a relatively thick panel of, for example, from 20 to 100mm, will utilise particles having a size range between about 2mm and Decorative panels and panels used for thermal and/or acoustic insulation purposes may be of a thickness of between 5 and 50mm, and may have a particle size ranging from between 100 microns and 1 to 2mm.

The particles 18 of the selected size range are mixed with a binder which is preferably an organic or inorganic resin. In one embodiment of the invention, the binder may be sodium silicate which imparts strong and rigid physical properties to the cured core structure. Silicate may cure (dry) in air or the curing may be accelerated by application of heat.

The panel core 14 may be formed separately from the facing sheets 16 and 17, and the sheets then adhered to the formed core 14 by a suitable adhesive. Thus, a layer of a mixture of particles 18 and the selected binder is formed into a layer of the intended thickness and shape, and the binder is set or cured to produce a relatively rigid 5 core structure. The selected facing sheets 16 and 17 are then adhered to the faces of the

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core 14 to form the completed sheet 12.

Alternatively, and depending on the binder used for the particles 18, a mixture N of the particles 18 and binder may be introduced between spaced facing sheets 16 and 17 and thereafter cured so as to integrally bond the facing sheets 16 and 17 to the core IN 10 14. The binder may be foamed within the panel so that the binder material fills all the voids between the particles 18 and provides substantially improved insulating properties.

Referring to Figure 3, a modified embodiment is shown in which the core 14 has a facing sheet 16 on one surface only, the opposite surface being un-faced to expose the foam glass particles thereby enhancing sound absorption properties of the panel. The sound absorption properties are particularly enhanced if the foam glass particles on the surface are sanded or other treated to open the granulate surface.

The core 14 of a panel formed in accordance with embodiments of the present invention is non-absorbent in the presence of moisture due to the use of non-absorbent foam glass particles. The panel may have a bulk density of as little as 150g/litre and, depending on the binder used and the material of the facing sheets, may be substantially non-flammable and fire resistant.

In a further embodiment of the invention, the core 14 may be formed using a predominant amount of foam glass granulate and a lesser amount of another particle material including ground glass, synthetic plastics material, mineral materials including rock wool particles, or any other suitable filler. In a still further embodiment of the invention, the core 14 may be formed using foam glass granulate particles and fibrous material, such as carbon fibres, fibres formed of synthetic plastics material, wool and other natural fibres or the like.

Materials used in the core 14 apart from the foam glass granulate particles will be selected in accordance with the intended use of the panel, the structural strength required and other properties that may be imparted by the particular material selected.

As stated above, the core material of the invention is preferably used in the manufacture of panel structures that are able to be used in building construction, Spartitions, doors, ceiling and wall facings, furniture, and for any other appropriate purpose. The core material may also be used as a lightweight, insulating filler or infill for any purpose. Thus, the core material may be formed in situ within a hollow structure by mixing the glass granules with a binder and filling, or partially filling the C'5 structure whereupon, on curing of the binder, the glass granules take the shape of the

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00 body. Decorative structures as well as functional structures may be formed using the N core material of this invention in this manner.

N The building material of the invention may be used as an acoustic absorber or as sound insulation. As indicated above, the acoustic absorption properties may be CI 10 enhanced by sanding or otherwise exposing or opening the foam glass granulate surface The present embodiments described above are specific examples of embodiments of the invention and, therefore, are to be considered in all respects as illustrative and not restrictive.

Claims

1. A building material particularly suitable for use in the manufacture of a panel, said material being formed of foam glass granulate and a granulate binder that 5 binds the granulate together to form a substantially rigid body. 00

2. A building material according to claim 1 wherein the foam glass granulate material has a particle size in the range of from about 100 microns to 7 millimetres. I 10

3. A building material according to claim 1 or claim 2 wherein the foam glass granulate is a blown-glass product.

4. A building material according to claim 3 wherein the foam glass granulate is made from recycled glass.

A building material according to any one of claims 1 to 4 wherein the bulk density of the foam glass granulate is less than about 200 gram per litre, and the material is dimensionally stable up to at least about 900'C.

6. A building material according to any one of claims 1 to 5 wherein the binder is selected from an organic resin, an inorganic resin and a phenolic resin.

7. A building material according to any one of claims 1 to 6 wherein the binder is foamed within the material to fill voids between the foam glass particles

8. A building material according to any one of claims 1 to 6 formed as a rigid core layer, and further including a facing sheet on one or both surfaces of said layer

9. A building material according to claim 8 wherein said facing sheet is selected from metal, timber, including a relatively thin ply veneer, 3 or 5 ply timber sheets, plaster board, cardboard, paper, any form of laminate including plastic laminates, fibreglass, carbon fibre, synthetic plastics material, glass sheet, and woven or knitted fabric including fabric made from natural and/or artificial fibres including cotton, linen, wool, polyester, nylon, canvas.

A building material according to any one of claims 1 to 9 wherein a facing sheet is adhered to rigid body using an adhesive separate from the binder.

11. A building material according to any one of claims 1 to 9 wherein a facing N, 5 sheet is adhered to the rigid body using the binder as an adhesive. 00

12. A panel comprising a core formed of foam glass granulate and a granulate binder that binds the granulate together to form a substantially rigid body, and a facing Ssheet on at least one side of the body, the facing sheet being adhered thereto. C~1

13. A panel according to claim 12 wherein the foam glass granulate material has a particle size in the range of from about 100 microns to 7 millimetres.

14. A panel according to claim 12 or claim 13 wherein the foam glass granulate is a blown-glass product.

A panel material according to claim 14 wherein the foam glass granulate is made from recycled glass.

16. A panel according to any one of claims 12 to 15 wherein the bulk density of the foam glass granulate is less than about 200 gram per litre, and the material is dimensionally stable up to at least about 900'C.

17. A panel according to any one of claims 12 to 16 wherein the binder is selected from an organic resin, an inorganic resin and a phenolic resin.

18. A panel according to any one of claims 12 to 17 wherein the binder is foamed within the material to fill voids between the foam glass particles

19. A panel according to any one of claims 12 to 18 wherein said facing sheet is selected from metal, timber, including a relatively thin ply veneer, 3 or 5 ply timber sheets, plaster board, cardboard, paper, any form of laminate including plastic laminates, fibreglass, carbon fibre, synthetic plastics material, glass sheet, and woven or knitted fabric including fabric made from natural and/or artificial fibres including cotton, linen, wool, polyester, nylon, canvas.

A panel according to any one of claims 12 to 19 wherein the facing sheet is adhered to the rigid body using an adhesive separate from the binder. 00

21. A building material according to any one of claims 12 to 19 wherein the N facing sheet is adhered to the rigid body using the binder as an adhesive. N 10

22. A method of producing the building material of any one of claims 1 to 11 including the steps of mixing foam glass granulate material with a binder which will bind the individual particles, forming the mixture to a desired shape and curing the binder to form a rigid body

23. A method according to claim 22 wherein the binder comprises an organic or inorganic resin.

24. A method according to claim 23 wherein the binder is sodium silicate.

25. A method according to claim 22 wherein the curing time of the binder is regulated by temperature.

26. A method according to any one of claims 22 to 25 wherein the body is laminated with facing sheets on one or both sides which are secured to the core by a suitable adhesive.

27. A method according to claim 26 wherein each facing sheet is adhered to the body using an adhesive separate from the binder.

28. A method according to claim 26 wherein a resin binder and granulate material is contained, before curing, between the facing material, and is cured so that the facing material is adhered to the core using the binder resin as the adhesive.

29. A method according to any one of claims 22 to 28 wherein the binder is selected from, an organic resin, an inorganic resin and a phenolic resin.

A method according to any one of claims 22 to 29 wherein the binder is N, 5 foamed within the granulate material whereby the binder resin fills voids between the oO 0C foam glass granulate particles

31. A method of forming a building material suitable for use in an insulating panel comprising the steps of selecting an amount of foam glass granulate of 1 10 predetermined size range to form the material, mixing the selected granulate with a resin binder, forming a layer of said mixture of predetermined thickness, and curing the resin binder.

32. A method of forming a building material according to claim 31 including the step of adhering a facing sheet to one side of said layer.

33. A method of forming a building material according to claim 31 including the step of adhering a facing sheet to both sides of said layer

34. A method of forming a building material according to any one of claims 31 to 33 including the step of selecting granulate in the size range of 100 microns to 7 millimetres.

A method of forming a building material according to any one of claims 31 to 34 including the step of forming said layer to a thickness of between 5 and 150 millimetres.

36. A method of forming an insulating panel comprising the steps of selecting an amount of foam glass granulate of a size range of between about 100 micron and 7 millimetres to form the panel, mixing the selected granulate with a resin binder, forming a layer of said mixture of predetermined thickness between about 5 millimetres and 150 millimetres, curing the resin binder, and adhering facing material to the opposed surfaces of the formed core.

S37. A building material particularly suitable for use in the manufacture of a panel substantially as hereinbefore described with reference to the accompanying drawings.

38. A panel substantially as hereinbefore described with reference to the 00 accompanying drawings. N N

39. A method of forming an insulating panel substantially as hereinbefore Sdescribed with reference to the accompanying drawings. (N A method of forming a building material suitable for use in an insulating panel having the steps substantially as hereinbefore described. Dated this twenty-fourth day of January 2005 Liquid Plastics Co. Pty. Ltd. Patent Attorneys for the Applicant: F B RICE CO