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WO2006016200A1 - Matériau de construction électriquement conducteur et processus pour fabriquer celui-ci - Google Patents

Matériau de construction électriquement conducteur et processus pour fabriquer celui-ci Download PDF

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Publication number
WO2006016200A1
WO2006016200A1 PCT/IB2004/002492 IB2004002492W WO2006016200A1 WO 2006016200 A1 WO2006016200 A1 WO 2006016200A1 IB 2004002492 W IB2004002492 W IB 2004002492W WO 2006016200 A1 WO2006016200 A1 WO 2006016200A1
Authority
WO
WIPO (PCT)
Prior art keywords
electrically conductive
material according
building material
gypsum
amorphous carbon
Prior art date
Legal status (The legal status 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 status listed.)
Ceased
Application number
PCT/IB2004/002492
Other languages
English (en)
Inventor
Ronald Bennett
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
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 Individual filed Critical Individual
Priority to PCT/IB2004/002492 priority Critical patent/WO2006016200A1/fr
Priority to EP04744143A priority patent/EP1773731A1/fr
Publication of WO2006016200A1 publication Critical patent/WO2006016200A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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
    • 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
    • C04B28/14—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 calcium sulfate 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
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/022—Carbon
    • 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
    • C04B2111/00241—Physical properties of the materials not provided for elsewhere in C04B2111/00
    • C04B2111/00422—Magnetic properties
    • 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
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00862—Uses not provided for elsewhere in C04B2111/00 for nuclear applications, e.g. ray-absorbing concrete
    • 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
    • C04B2111/40—Porous or lightweight materials
    • 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
    • C04B2111/90—Electrical properties
    • C04B2111/94—Electrically conducting materials

Definitions

  • the present invention concerns an electrically conductive building material comprising graphite particles and amorphous carbon, in particular plaster and a process for producing it.
  • 5,908,584 to Bennett discloses electrically conductive concrete comprising a mixture of graphite, amorphous carbon and sand with a cement binder for making a coating or mortar, a sandwich shaped construction panel, and building blocks.
  • WO00/69789 to MANTLE & LLAY LTD et al provides a concrete or cementitious product having one or more forms of carbon dispersed therethrough so as to reduce thermal conductance across the product.
  • the one or more forms of carbon are preferably dispersed therethrough in small clusters and/or agglomerates that are wholly or substantially isolated from each other.
  • a high percentage of carbon in a cement mix reduces the strength of the product making it brittle, fragile and subject to fracture, which can interrupt the conductivity, and make the shielding unreliable. This effect can be overcome to an extent by subjecting the mixture to pressure during the setting process, or by the addition of additives, both of which add to the cost .
  • cementitious products take many years to dry out completely. Whether as mortar, building blocks or poured concrete, cement retains some free water radicals even when it is set and apparently dry. Many substances, and in particular steel and other metals, in contact with the material are subjected to chemical and electrolytic action, causing long term corrosion or chemical change.
  • cement mortars and plasters are subject to minute fracturing, and the products have to be made thick to achieve their strength.
  • the aim of the present invention is:
  • the electrically conductive material according to the present invention comprises graphite particles having a particle size not greater than about 12 microns and amorphous carbon, bound in a gypsum/carbon matrix.
  • the matrix comprises a crystalline lattice of gypsum integrated with amorphous carbon.
  • Various embodiments are claimed in claims 3 to 22.
  • the invention relates also to a process for producing the electrically conductive material wherein a portion of amorphous carbon is mixed dry with the gypsum, water is then added to start the hydration process, producing a supersaturated solution in which crystals start to form and as the crystals coalesce, minute particles of amorphous carbon become incorporated into the lattice causing it to become electrically conductive, the rest of amorphous carbon is mixed with the graphite separately, coating it, and the mixture is added to the hydrating solution as the crystallisation accelerates, trapping the coated electrically conductive graphite particles between the interlocking crystals which form a binding matrix
  • the gypsum matrix has properties not present in cementitious or other products, which give the material according to the present invention unique electrical, chemical and physical characteristics.
  • the hydration is uniform throughout the mixture.
  • the uniformity of the hydration ensures uniformity in the distribution of the carbons throughout the mixture, so the electrical conductivity is not jeopardised by incomplete mixing.
  • mixing and wetting of the hemihydrate powder, which causes disintegration of the hemihydrate particles is followed by a short induction period, after which nuclei begin to form from the supersaturated solution. The hemihydrate is converted directly into dihydrate.
  • the anhydrite also converts directly into the dihydrate without converting to hemihydrate, and so may not form the same supersaturated solution. As the hydration proceeds and the slurry sets, dihydrate crystals grow, intergrow and interlock. (U.Ludwig, J.K. Kuh.lma.nn, Tonind, Ztg. Keram. Rundsch. 98 (1974) 1- 4).
  • This carbon combination will not be absorbed into the lattice, but will be trapped with residual particles of amorphous carbon larger the minute ones (nano particles) from the first mix, in the matrix by the interlocking of the forming crystals, forming a consistent highly conductive material.
  • Another advantage of the material according to the present invention is the fact that the graphite becomes locked into the matrix, making the plaster strong and not subject to fracture.
  • a higher percentage of carbons can be included in the mixture without weakening the material or making it brittle or fragile, so reliable shielding is provided with thin plaster coatings.
  • Another advantage of the material according to the present invention is the fact that part of the conductive amorphous carbon becomes integrated into the crystalline gypsum lattice. This carbon is evenly and closely dispersed and, together with the graphite bound by the matrix, provides a material capable of withstanding bombardment from Maser amplified radiation. Recent research in nanotechnology has shown that minute particles of less than 10 nanometers display unusual properties, which enables them to interact with molecules within crystals. The sophisticated equipment needed to produce such particles normally makes them very expensive to produce and their derivatives highly expensive.
  • An advantage of the material according to the present invention is that it uses carbon. This is the only substance, which produces nano particles naturally.
  • the gasses produced from the incomplete combustion of organic material produce a deposit of amorphous carbon part of whose particles are of nano size. This requires no sophisticated equipment, and is often produced as a by-product of other processes, so enabling the present invention to benefit from nanotechnology without incurring any high cost.
  • gypsum (CaSO 4 " 2H 2 O) , is chemically stable.
  • any spare water evaporates off.
  • the plaster being completely dry and chemically inert, there is no metallic corrosion or chemical reaction with other substances. This simplifies connection between the plaster and other electrically conductive components such as doors, vents and windows in a shielded enclosure.
  • Gypsum adheres to gypsum. Since the material according to the invention has the same physical properties gypsum plaster without carbons will adhere to that material .
  • the colour of the material according to the present invention is also grey, but a layer of pure gypsum plaster, which is white and opaque, will adhere to the material and provide a smooth white surface, which can be painted or papered to give an aesthetically pleasing finish.
  • Gypsum is an insulator.
  • a layer of pure gypsum plaster will adhere to the material according to the invention and can be used to an insulate it electrically.
  • the gypsum hydration process gives out heat, and the reaction time is short.
  • Another advantage of the material according to the present invention is the fact that the heat given out during hydration prevents delays caused by water freezing during setting in cold weather, and the reaction time, which keeps setting time short, makes the plaster easy to apply.
  • Gypsum is a flame retardant, so the material according to the present invention also acts as a flame retardant.
  • gypsum dihydrate changes to hemihydrate or anhydrite, releasing water.
  • a further advantage of the material according to the present invention is the fact that gypsum has a more simple chemistry and crystalline structure than that of cement .
  • the chemical reactions consist of dehydration and hydration of the gypsum ingredients, as described above, and the crystals are uniformly monoclinic with three axes, one pair not at right angles, and one direction of perfect cleavage. This allows for some slip along the line of cleavage where the ions are linked by water, when the material is subjected to stress or percussion.
  • the basic structure is held firm by the intergrowth and interlocking of the crystals described above.
  • the heavy broken line indicates the cleavage, which breaks only hydrogen bonds.
  • the material according to the present invention has excellent workability, and can be made into plasterboard, partitions, ceiling and floor tiles, fibre-reinforced boards and pre-cast panels Due to the plasticity described above these components are shock resistant and will not shatter under attack.
  • ⁇ - hemihydrate as the starting gypsum ingredient, the material can be made into a mortar which adheres to any masonry surface, including gypsum surfaces, does not crack, expands slightly on setting, and sets fast. This mortar can be used to connect the electrically conductive components for use in the rapid construction of prefabricated or portable Faraday Cages for military or civilian installations.
  • the weight of amorphous carbon mixed with the gypsum represents at least 1%, preferably between 1% and 5%, of the weight of gypsum.
  • the weight of the amorphous carbon .mixed with the graphite represents at least 2%, preferably between 2% and 10%, of the total weight of the graphite.
  • the total weight of the graphite represents between 15% and 75% of the total weight of the material .
  • the material comprises glass fibres and or magnetic or magnetisable metallic molecules.
  • the amorphous carbon comprises nano particles of 1 to 10 nanometres.
  • The- proportion of nano particles in the portion of amorphous carbon mixed with the gypsum represents at least 1%, preferably 1% to 50% of the amorphous carbon weight.
  • the material according to the invention can be used principally in the following ways :
  • One or other of these six forms of material according to the invention can be used to provide an electrically conductive lining to a room or building, which will attenuate radiation and shield the contents from electromagnetic interference.
  • the material can be used to provide attenuation in the surface of a room or building to protect it from X-rays or Gamma rays, so providing shielding for hospitals, laboratories and other sensitive installations vulnerable to intentional or unintentional bombardment from such radiation.
  • the material can be used in military command posts and other sensitive installations to shield them from bombardment by Maser amplified microwave radiation beams.
  • panels of the material can be used as reflectors to shield schools and other buildings from radiation from Cellular Telephone Base Station transmission, which is feared to be damaging to health.
  • the render made from the material of the invention may be plastered over damaged masonry surfaces.
  • Roof, Ceiling and Wall covering from the material of the invention may be used to protect the occupants of rooms or buildings from bombardment from mentally destabilising EMR weapons.
  • the material of the invention may be used to provide a flame-retardant electrically conductive EMI shield for rooms and buildings to give the occupants more time in case of fire or attack.
  • the material of the invention may be used to provide a shock-resistant electrically conductive EMI shield for rooms and buildings to protect the occupants and contents from damage caused by shattering or cracking of walls or wall surfaces in the event of an earthquake or bomb attack.
  • the attenuation attained by the material according to the invention can be > 4OdB over a range of frequencies of IMHz to 18 GHz. Attenuation varies according to the ratio of carbons to gypsum in the mixture. With the high proportion of carbons tolerated by gypsum before it weakens, attenuation up to 6OdBs can be achieved across most frequencies in this band. With the inclusion of Barium Sulphate in the mixture, the frequency range of attenuation can be extended to include X-rays and Gamma rays.
  • the heating properties of the material according to the present invention are characterised by the fact that it acts as a semi-conductor with the resistivity increasing with temperature. This makes it more efficient at lower temperatures ( ⁇ 40° C)-, and there is only one heat exchange, such as heating water, so reducing the power consumption.
  • Another embodiment of the invention sets the wires or busbars connecting the products or components made from the material according to the invention in non-carbon gypsum to insulate them electrically.
  • Another embodiment of the invention uses a layer of material according to the invention in plasterboard to provide low temperature invisible wall heating.
  • Another embodiment of the invention uses wainscoting made from the material according to the invention to provide low level, invisible wall heating.
  • Another embodiment of the invention uses floor tiles made from the material according to the invention to provide floor heating.
  • Another embodiment of the invention uses thick tiles for use in storage heaters, to take advantage of electricity off-peak tariff incentives.
  • Another embodiment of the invention uses thick floor tiles to provide storage floor heating.
  • Another embodiment of the invention uses ceiling or roof tiles made from material according to the invention to prevent settling or ice forming on roofs in cold regions, in particular ski resorts and areas with heavy snowfalls, where heavy accumulation of snow on roofs constitutes a danger.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Civil Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Building Environments (AREA)
  • Shielding Devices Or Components To Electric Or Magnetic Fields (AREA)

Abstract

L’invention concerne un matériau plâtreux électriquement conducteur comportant un mélange de graphite, de carbone amorphe et de gypse, pour la protection contre les radiations électromagnétiques et pour chauffer. Il a été démontré que ce mélange présente d’excellentes propriétés de protection dans la plage des 1 MHz à 18 GHz et peut être constitué pour inclure les faisceaux de rayons X, de rayons gamma et de radiations amplifiées par maser. Il est d’application facile et peut être utilisé en tant qu’enduit ou formé en plaques de plâtre, en panneaux de cloisonnement ou en tuiles, et est un retardateur de flamme et résistant aux chocs. Il peut également être utilisé en tant que matériau chauffant économique sûr, s’installe facilement et peut être employé dans des maisons, des bureaux, pour le dégivrage et pour empêcher l’accumulation de la neige.
PCT/IB2004/002492 2004-08-04 2004-08-04 Matériau de construction électriquement conducteur et processus pour fabriquer celui-ci Ceased WO2006016200A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
PCT/IB2004/002492 WO2006016200A1 (fr) 2004-08-04 2004-08-04 Matériau de construction électriquement conducteur et processus pour fabriquer celui-ci
EP04744143A EP1773731A1 (fr) 2004-08-04 2004-08-04 Matériau de construction électriquement conducteur et processus pour fabriquer celui-ci

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/IB2004/002492 WO2006016200A1 (fr) 2004-08-04 2004-08-04 Matériau de construction électriquement conducteur et processus pour fabriquer celui-ci

Publications (1)

Publication Number Publication Date
WO2006016200A1 true WO2006016200A1 (fr) 2006-02-16

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Country Status (2)

Country Link
EP (1) EP1773731A1 (fr)
WO (1) WO2006016200A1 (fr)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2045219A1 (fr) * 2007-10-05 2009-04-08 Knauf Gips KG Procédé de fabrication d'un panneau de construction à base de sulfate de calcium-sulfate de baryum
WO2009047228A1 (fr) * 2007-10-05 2009-04-16 Knauf Gips Kg Procédé pour fabriquer un panneau de construction à base de sulfate de calcium-sulfate de baryum
WO2011078708A1 (fr) * 2009-12-24 2011-06-30 Carbon Credit Corporation New Zealand Limited Plaque de plâtre au carbone
WO2011095634A1 (fr) 2010-02-08 2011-08-11 Knauf Gips Kg Plaque en placoplâtre et procédé de fabrication d'une plaque en placoplâtre
DE202018003113U1 (de) 2018-01-19 2018-10-11 Philipp Klett Feuchtigkeitssensor enthaltendes Bauelement zur Steuerung einer Smart-Home-Vorrichtung
US10184670B2 (en) 2009-11-05 2019-01-22 Winstone Wallboards Limited Heating panel and method therefor
CN111574086A (zh) * 2020-05-27 2020-08-25 重庆大学 微波除冰功能水泥基材料的集料及水泥基材料和制作方法
GB2592848A (en) * 2019-07-26 2021-09-15 Marlborough Brickwork Ltd Construction material

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1508866A (en) * 1974-07-01 1978-04-26 Mitsubishi Petrochemical Co Gypsum compositions for producing shaped articles
US5908584A (en) * 1994-06-24 1999-06-01 Elfinco S.A. Electrically conductive building material
WO2004065322A1 (fr) * 2003-01-24 2004-08-05 Ronald Bennett Materiau de construction

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1508866A (en) * 1974-07-01 1978-04-26 Mitsubishi Petrochemical Co Gypsum compositions for producing shaped articles
US5908584A (en) * 1994-06-24 1999-06-01 Elfinco S.A. Electrically conductive building material
WO2004065322A1 (fr) * 2003-01-24 2004-08-05 Ronald Bennett Materiau de construction

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2045219A1 (fr) * 2007-10-05 2009-04-08 Knauf Gips KG Procédé de fabrication d'un panneau de construction à base de sulfate de calcium-sulfate de baryum
WO2009047228A1 (fr) * 2007-10-05 2009-04-16 Knauf Gips Kg Procédé pour fabriquer un panneau de construction à base de sulfate de calcium-sulfate de baryum
US10184670B2 (en) 2009-11-05 2019-01-22 Winstone Wallboards Limited Heating panel and method therefor
WO2011078708A1 (fr) * 2009-12-24 2011-06-30 Carbon Credit Corporation New Zealand Limited Plaque de plâtre au carbone
WO2011095634A1 (fr) 2010-02-08 2011-08-11 Knauf Gips Kg Plaque en placoplâtre et procédé de fabrication d'une plaque en placoplâtre
CN104136216A (zh) * 2010-02-08 2014-11-05 可耐福石膏两合公司 石膏灰泥板和制备石膏灰泥板的方法
AU2011212357B2 (en) * 2010-02-08 2014-12-18 Knauf Gips Kg Gypsum plaster board and a method for producing a gypsum plaster board
EA022141B1 (ru) * 2010-02-08 2015-11-30 Кнауф Гипс Кг Панель гипсокартона и способ изготовления панели гипсокартона
US9283732B2 (en) 2010-02-08 2016-03-15 Knauf Gips Kg Gypsum plaster board and a method for producing a gypsum plaster board
DE202018003113U1 (de) 2018-01-19 2018-10-11 Philipp Klett Feuchtigkeitssensor enthaltendes Bauelement zur Steuerung einer Smart-Home-Vorrichtung
GB2592848A (en) * 2019-07-26 2021-09-15 Marlborough Brickwork Ltd Construction material
CN111574086A (zh) * 2020-05-27 2020-08-25 重庆大学 微波除冰功能水泥基材料的集料及水泥基材料和制作方法

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