Clay building board and process for producing it

Details Clay building board and process for producing it Clay building board and process for producing it

1992-11-25

1994-06-21

Cannon, James C.

Stock material or miscellaneous articles

Composite

Of carbohydrate

156142, 264333, 428703, B32B 1302

Patent

active

053227387

DESCRIPTION:

BRIEF SUMMARY
The invention pertains to a clay building board consisting of a clay-bound core layer covered on both sides with a surface layer as well as a process for producing a clay building board of this type.
The building material clay has decisive advantages over conventional, industrialized building materials. It has the ability to regulate air humidity in rooms and thus to create a healthy living environment. However, compared to conventional, industrialized building materials, the use of clay building materials generally involves a greater amount of labor. One of the decisive advantages of clay construction, namely, inexpensive starting materials, is thus offset by the greater processing time. To counteract this problem, attempts have already been made to shift as many activities as possible away from the construction site and towards industrial or semi-industrial prefabrication.
EP-A-128 681 describes a clay building board of the type specified above. Its clay-bound core layer contains expandable minerals and reinforcement in the form of fibers. The core layer is covered on both sides with a surface layer made of paper.
The invention pertains to boardlike finished parts of this type that use clay as the binder. The term "clay building board" is defined as a clay finished part shaped in the form of a board. Clays that can be used include especially light clay and in this category especially straw light clay or clay with porous mineral additives. The term "board" is defined here as a member with essentially flat main surfaces, whose dimensions in length and width are essentially arbitrary, but in any case can be several meters, and whose thickness can vary between a few centimeters and a few decimeters.
WO 87/04976 describes a cement-bound building board, which is reinforced by a network of glass fibers, which is embedded near the surface. DE-A-18 13 733 concerns a very generally described, hydraulically bound building board, which is reinforced by a netlike plastic material, which is either embedded entirely near the surface or merely rests on the surface. U.S. Pat. No. 1,604,236 describes a cement-bound building board, in which a net is embedded near one of the main surfaces. It is intended to prevent coarse fiber components of the still plastic core material from being able to adhere to the pressing rolls during the production process.
The goal of the invention is to develop a clay building board of the type specified, and a process for producing it. It should be possible to produce the clay building board industrially in any desired dimensions. It should be stable and easy to handle. In particular, is should be easy to transport and easy to cut. In addition, it should have a sufficiently firm surface.
The goal of the invention is achieved by a clay building board with the features specified in the claims.
Clay building boards of this type can be industrially produced in any desired size. Due to the surface layers on both sides, they have excellent strength. They can be cut to any desired size by simple means, e.g., a hand saw or a power saw. The netlike material and the clay in the core layer are joined by superficially embedding the textile material in the clay of the core material. This results in an interlocking connection. Special additional binders are not needed. The material is embedded only so deep that the netlike structure of the textile material determines the surface of the clay building board, i.e., it is immediately recognizable from the outside. The superficially visible textile layer gives the clay building board a basically regular, relief-like structure, and, for example, when used for interior walls, the clay building board can be directly painted without any need to first apply plaster or wallpaper. This represents a significant processing simplification.
The clay building board is produced from natural materials. The textile material is especially fabric, specifically, coarse fabric made from flax, cotton and similar, naturally growing fibers. The textile layer must have a netlike struct

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Luasanne C. H., "Lightweight Building Panel Made of Phenolic and Foamed Clay", Modern Plastics, vol. 42, No. 6, Feb. 1965, p. 46.

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