Plastic and nonmetallic article shaping or treating: processes – Mechanical shaping or molding to form or reform shaped article – To produce composite – plural part or multilayered article
Patent
1992-02-18
1995-06-06
Ryan, Patrick J.
Plastic and nonmetallic article shaping or treating: processes
Mechanical shaping or molding to form or reform shaped article
To produce composite, plural part or multilayered article
264219, 264241, 264250, 264252, 264255, 264261, 264267, 264275, B29C 4120
Patent
active
054220564
DESCRIPTION:
BRIEF SUMMARY
This invention relates to a method of manufacturing glass reinforced concrete building products. It relates particularly but not exclusively to a method of manufacturing glass reinforced concrete panels suitable for use as acoustic barriers.
Glass reinforced concrete has been used for several years as a building material in such applications as partitioning, linings, fascias, facades, cladding, curtain walling, spandrels, fencing and other similar such applications. Glass reinforced concrete (hereinafter referred to as "GRC") is made from a combination of Portland cement and silica sand reinforced with glass fibre (usually alkaline resistant glass strands).
GRC is known to be good acoustic barrier material because of its ability to reduce sound transmission. For example, a typical 10 mm thickness of GRC has a sound transmission loss of about 30 dB. GRC is particularly suitable for sound damping applications adjacent highways and motorways, but its use has not been fully exploited because the glass fibres in GRC are sharp, GRC tends to be rough, and adequate methods of manufacturing using GRC have not been developed.
In the particular application of roadside noise damping, it has been discovered that effective results are achieved if a wall comprised of GRC panels is placed beside the road. Each of the panels is constructed in such a way that the panel has reflective, dispersive or absorptive characteristics, or a combination of these. It is desirable that the panels in the wall be arranged contiguously.
The acoustic properties of individual GRC panels will depend to some extent upon the construction of those panels. Thus, while a suitable panel may be comprised of two or more pieces screwed or glued together, it is more desirable that a panel be formed in a single moulding operation. This is because joints have an inherently deleterious effect on the acoustic properties of a panel, and the securing together of GRC sheets is a labour intensive task.
It is a known technique for cast-moulding to use a two-part mould wherein, after the object in the mould has hardened, the parts of the mould are separated and the object can be removed. However, such a moulding technique is generally suitable only for solid or substantially solid objects. The present invention develops the known cast-moulding technique to create a new method of cast-moulding substantially hollow objects.
It is an object of this invention to provide a method of manufacturing GRC panels. Another object of this invention is to provide a method of manufacturing GRC panels in such a way that the GRC panels are suitable for contiguous installation. A further object of this invention is to provide a method of manufacturing a single piece GRC panel.
According to one aspect of the present invention, there is provided a method of manufacturing a glass reinforced concrete building product, comprising: about an axis which is adjacent an edge of each of the two parts of the mould; layer of glass reinforced concrete; concrete to harden, forming a single building product.
As a preferred feature, step (b) includes the placing of one or more additional mould elements at or near one or more edges of one or both parts of the mould, in order to cause one or more edge portions of the finished building product to have a particular shape. It is preferred that the edge-shaping be accomplished by use of this technique rather than by shaping after the GRC has hardened because it is difficult to modify the shape of hardened GRC, and such modifications tend to lead to weakness in the finished products.
According to another aspect of the present invention, there is provided a two-part mould wherein the two parts are hinged together about an axis which is adjacent an edge of each of the two parts of the mould. This mould is suitable for use in the method previously described.
According to a further aspect of the invention, there is provided a hollow GRC panel made according to the method previously described. The preferred panel has four edges, with channels extending along
REFERENCES:
patent: 2892339 (1959-06-01), Flower et al.
patent: 3324967 (1967-06-01), Robinson
An article "Highway Engineering in Australia" in Nov. 1988 by Gernot Schubert (Exhibit A).
Neu Steven Bernd
Ryan Patrick J.
Weisberger Richard
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