Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Cellular products or processes of preparing a cellular...
Patent
1984-08-21
1986-08-19
Anderson, Philip
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Cellular products or processes of preparing a cellular...
264 453, 264 462, 264DIG7, 425117, 425261, 425817R, 521917, C08G 1814, B29C 6716, B29C 6722
Patent
active
046070613
DESCRIPTION:
BRIEF SUMMARY
The present invention relates to a building material for a building element in the shape of a plate, block, beam or column and consisting of a compressed, hard, particle-shaped filler, the particles of which are held together by a foam plastic material.
Lightweight building elements of foam plastic, containing as admixture and economizing means a filler in the shape of hard particles, are generally known. In manufacturing these known building materials it is attempted to achieve a distribution of the particles of maximum uniformity, and a complete embedment of each particle in a surrounding mass of foam plastic. A prior art building element of this kind may be produced, e.g. as described in the German Published Patent Specification No. 2056063, where a mixture of particles and perlite and polyurethane foam is compressed in a mould by the upper portion of the mould being pressed down into the lower portion thereof at the same time while the foaming is taking place. The compression, however, is not stronger than that the frothing agent is deposited between the particles in a way described as "a kind of mesh formation of the frothing agent in the Perlit-filling".
While the prior art building elements of the kind in question are developed with a special view to producing heat and sound insulating lightweight building elements, it is the object of the present invention to provide a cheap building material which in addition to its good insulating and fire-restraining qualities comprises such a strength as well that it can be used as a supporting element in building constructions, e.g. in such a manner that they can replace usual reinforced concrete building elements which regarding weight as well as insulating qualities are inferior to the building elements according to the invention. Furthermore, it is the object of the invention to provide a method and a system for manufacturing building elements.
The building material according to the invention is characteristic in that the particles of the filler are so firmly compressed that they form a coherent supporting skeleton or framework, and that the foam plastic material, preferably a polyurethan foam, is occurring only in a precisely sufficient amount for filling the existing natural cavities between the firmly compressed particles for cementing the particles together.
The filler is compressed so firmly in the mould that after the foaming the grains will still touch each other. This is the condition of obtaining high compression strengths.
Such a building material comprises a great number of favourable qualities, which it has not been possible to combine in any hitherto known homogenous building material. The self-supporting framework and the limitation of the foam material to the natural cavities therein cause the building material to combine a high strength and stability against contraction and shrinkage with excellent fire-restraining qualities and highly satisfactory surface qualities. In case of fire, the material is in fact self-extinguishing, and the relatively great amount of particles (e.g. 85-90% leca) and the corresponding small amount of foam plastic (e.g. 10-15% polyurethane) moreover have the effect that the problems generally occurring in connection with casting of thick elements of foam material owing to developed heat destroying the foam, are eliminated in consequence of the reduced generation of heat from the foam and the absorption by the particles of the surplus heat. The tensile strength of the material is furthermore easily improved by embedding fibres or inserting reinforcement, e.g. of aluminium. In addition to improving the tensile strength, inorganic fibres will in case of fire have a stabilizing effect, as when melting they cooperate to cement the inorganic filler together so that this will not disintegrate when the foam plastic material carbonizes. This results in a sintering of the material which acts as a heat shield preventing a further intrusion of fire. The material is easily workable, it will hold nails and can be glued. The surfa
REFERENCES:
patent: Re25564 (1964-04-01), Alford et al.
patent: 3025202 (1962-03-01), Morgan et al.
patent: 4011183 (1977-03-01), Ruff
patent: 4072788 (1978-02-01), Herweg et al.
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