GB2471343A

GB2471343A - Gypsum and polymer building profile and a method of using waste gypsum to make a profile

Info

Publication number: GB2471343A
Application number: GB0913158A
Authority: GB
Inventors: Perry Day
Original assignee: Individual
Current assignee: Individual
Priority date: 2009-06-25
Filing date: 2009-07-29
Publication date: 2010-12-29
Also published as: GB0911111D0; GB0913158D0

Abstract

The building profile comprises a polymer and gypsum. The gypsum can be comminuted waste material which is mixed with the polymer to act as filler and the profile may incorporate a defined body of homogenous gypsum filled polymer. The rear of the profile may comprise a gypsum filled polymer body 10 and the front of the profile may comprise a gypsum-free polymer capping layer 11 which is clipped to the body where the front and the rear of the profile extend at least partially parallel to each other. The polymer may be a thermosetting plastic or thermosetting resin. Also claimed is a method of using gypsum waste which includes comminuting the gypsum mixing it with a then nosetting polymer or resin to act as a filler, and forming a building profile by moulding or extrusion.

Description

BUILDING PROFILE

TECHNICAL FIELD OF THE INVENTION

This invention relates to building construction and refurbishment.

BACKGROUND

Gypsum is a high sulphate material and is regarded as an environmental contaminant. As of 1 April 2009, United Kingdom Environment Agencies have revised their policies for disposing of gypsum waste to landfill.

Previously, waste containing less than 10% gypsum could be sent to landfill, but this permitted value has now been removed and waste containing any amount of gypsum must now go to a separate cell for disposal of high sulphate waste.

This presents a major problem for the building industry which traditionally produces large quantities of gypsum waste. Gypsum plasterboard is widely used for covering walls and ceilings, and for each metre of plasterboard which is used approximately 10% is discarded as offcut waste. Disposal of large quantities of gypsum waste is very costly.

Known ways of recycling gypsum waste include reuse as a raw material in the manufacture of new plasterboard and other gypsum-based products, use as a soil treatment agent, and use as an additive for cement clinker.

However, plasterboard using recycled gypsum waste is more costly than virgin plasterboard. Furthermore, using recycled plasterboard still produces around 10% of waste.

The present invention seeks to provide a new and inventive way of reusing gypsum waste materials within the building industry.

SUMMARY OF THE INVENTION

The present invention proposes a building profile which includes a polymer and gypsum.

The gypsum may be comprised in comminuted waste material and mixed with the polymer to act as a filler.

The profile may incorporate a defined body of gypsum-filled polymer which is preferably disposed adjacent to a substantially planar rear face of the profile. Although the gypsum filled polymer may be substantially homogeneous throughout the profile an opposite front face of the profile is preferably provided by a decorative capping layer of non-gypsum-filled polymer or other aesthetically acceptable material. The capping layer may be separable from the gypsum-filled layer, and may be adapted to clip onto the body of gypsum-filled polymer.

The polymer may comprise a thermosettirg plastic or a thermosetting resin.

The invention also provides a method of using gypsum waste which includes comminuting the waste material, mixing it with a thermosetting polymer or resin to act as a filler, and forming the building profile using the gypsum filled material.

BRIEF DESCRIPTION OF THE DRAWINGS

The following description and the accompanying drawings referred to therein are included by way of non-limiting example in order to illustrate how the invention may be put into practice. In the drawings: Figure 1 is a transverse cross section through a skirting profile in accordance with the invention; and Figure 2 is a similar transverse cross section through a second form of skirting profile in accordance with the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

Fig. I shows a building profile in the form of a length of skirting of the kind which is attached to a wall immediately above floor level. Various profiles can be used, but the drawing shows a common form of plain profile for purposes of illustration. The profile can be formed in suitable lengths such as 2.4 metres, 3.6 metres, 4.8 metres etc. The profile I has generally planar and parallel front and rear faces 2 and 3 joined by a relatively short bottom face 4. The front face 2 is visible in use and is generally provided with a decorative profile at or near its upper end, represented here by a simple chamfer 5. In use, the rear face 3 is fixed to the wafl by means of a high strength adhesive, nails, screws etc. The skirting profile may be formed from various thermosetting polymers or resins incorporating ground gypsum waste. Various methods may be used, several examples of which now follow.

EXAMPLE 1

The profile can be formed by compression moulding with a gypsum filled thermosetting polymer forming a layer 6 adjacent to the rear face 3. A capping layer 7 of a virgin or recycled polymer, filled or unfilled, is used to give an acceptable appearance on the front face 2. The moulded components form a sandwich with the good surface exposed on the front face 2. It will be appreciated that the layers can vary in thickness, the drawing being purely illustrative of one possible configuration. Since the rear face 3 is not visible the gypsum layer is not detrimental to the appearance of the skirting section in use.

EXAMPLE 2

The profile can also be formed by extrusion using a part gypsum filled thermosetting polymer and suitable additives to give a homogeneous white or coloured aesthetically pleasing appearance throughout the extruded profile.

EXAMPLE 3

The skirting profile can be formed as a co-extrusion using a partly filled gypsum polymer compound 6 co-extruded with a virgin or recycled polymer 7, filled or unfilled, with good aesthetic properties, to form a visible capping layer on the front face of the profile.

EXAMPLE 4

Fig. 2 shows another length of skirting, again of relatively plain profile, for attachment to a wall immediately above floor level, which can be formed in suitable lengths such as 2.4 metres, 3.6 metres, 4.8 metres etc. The profile has a body component 10 and a relatively thin capping component 11. The body 10 can be formed by compression moulding or extrusion of a part-gypsum-filled thermosetting polymer, whereas the capping 11 is extruded using a virgin or recycled polymer, filled or unfilled, to give an aesthetically acceptable appearance. The body 10 has generally planar and parallel front and rear faces 12 and 13 joined by a relatively short bottom face 14. The front face 12 is not visible in use since it is completely covered by the capping 11, but the front face will generally be provided with a decorative profile at or near its upper end, represented by the chamfer 15. Capping component 11 is shaped to conform to the front profile of the body 10, having a planer bottom section 16 and an angularly disposed top section 17. The lower end of the bottom section 16 is formed with a rear rib 18 which engages in a corresponding notch 19 formed in the body 10 at the junction between the front face 12 and the bottom face 14. The upper end of the capping 11 is formed with a rearwardly-projecting flange 20 having a further rib 21 which engages in a further notch 22 formed at the upper end of the rear face 13. Thus, when the rear face of body 10 is fixed to the wall by means of a high strength adhesive, nails, screws etc. the capping can be clipped onto the body forming a decorative cover. Since the body portion 10 is not visible the gypsum layer is not detrimental to the appearance of the skirting section.

Other means can be used to secure the capping 11 to the gypsum-filled body 10, e.g. a suitable high strength adhesive.

Although skirting profiles have been described herein for purposes of illustration it will be appreciated that the invention can also be applied to other kinds of building profile which are used in new build or refurbishment properties, e,g, architrave for surrounding doorways, dado rails, picture rails etc. Whilst the above description places emphasis on the areas which are believed to be new and addresses specific problems which have been identified, it is intended that the features disclosed herein may be used in any combination which is capable of providing a new and useful advance in the art.

Claims

CLAIMS1. A building profile which includes a polymer and gypsum.
2. A building profile according to Claim I in which the gypsum is comprised in comminuted waste material.
3. A building profile according to Claim I or 2 in which the gypsum is mixed with the polymer to act as a filler.
4. A building profile according to Claim 3 which incorporates a defined body of gypsum-filled polymer.
5. A building profile according to Claim 4 in which the defined body of gypsum-filled polymer is disposed adjacent to a substantially planar rear face of the profile.
6. A building profile according to Claim 5 in which an opposite front face of the profile is provided by a capping layer of non-gypsum-filled material.
7. A building profile according to Claim 6 in which the capping layer is formed of a non-gypsum-filled polymer.
8. A building profile according to Claim 6 or 7 in which the defined body of gypsum-filled material is separable from the capping layer.
9. A building profile according to Claim 8 in which the capping layer is adapted to clip onto the body of gypsum-filled polymer.
10. A building profile according to any of Claims 1 to 3 in which the gypsum filled polymer is substantially homogeneous throughout the profile section.
11. A building profile according to any preceding claim in which the profile has a substantially planar rear face and a front face at least part of which extends substantially parallel to the rear face.
12. A building profile according to Claim 11 in which the front face has a decorative profile at its upper end.
13. A building profile according to any preceding claim in which the polymer includes a thermosetting plastic.
14. A building profile according to any of Claims 1 to 12 in which the polymer includes a thermosetting resin.
15. A method of using gypsum waste which includes comminuting the waste material, mixing it with a thermosetting polymer or resin to act as a filler, and forming a building profile using the gypsum filled material.
16. A method of using gypsum waste according to Claim 15 in which the building profile comprises a component which is formed by compression moulding.
17. A method of using gypsum waste according to Claim 15 0116 in which the building profile comprises a component which is formed by extrusion.
18. A method of using gypsum waste according to Claim 16 or 17 in which the gypsum filled polymer is faced with a non-gypsum-filled polymer.
19 A building profile substantially as described with reference to the drawings.
20. A method of using gypsum waste substantially as described with reference to the drawings.