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Title:
ULTRA THIN, LESS THAN 1MM, MULTILAYER LAMINATES MADE UP OF HIGH PERFORMANCE POLYMER MODIFIED CEMENT MORTAR
Document Type and Number:
WIPO Patent Application WO/2020/012201
Kind Code:
A1
Abstract:
a. Multilayer film very thin (0,8-3,00mm) with two large sides as per Fig.1/5, which is made of more than one layers bonded together monolithically by means of interfacial grout layers. This film is used either as floor and wall cover or as constitutive Element of composite Elements. b. Composite Laminated Elements made of more than two individual multilayer ultrathin Films (a) bonded together by means of interfacial grout layers, Fig 2/5, 3/5 used as elements for Security of Buildings and installations against intrusion, or as decorative or structural Element, or as building elements of any kind. c. Closed Composite Elements made of one or more Multilayer very thin films (a) wrapped around lightweight core of Expanded Polystyrene, or Pumice Concrete, or Perlite Concrete or Cellular Concrete, Fig.4/5, used as elements for Security of Buildings and installations against intrusion, or as decorative or structural Element, or as building elements of any kind. d. Sandwich Elements made of one or more multilayer very thin film (a) bonded on the bottom and top sides of lightweight core of Expanded Polystyrene or Pumice Concrete, or Perlite Concrete or Cellular Concrete, Fig. 5/5,, used as elements for Security of Buildings and installations against intrusion, or as decorative or structural Element, or as building elements of any kind.

Inventors:
ZAVLIARIS KONSTANTINOS (GR)
Application Number:
PCT/GR2019/000041
Publication Date:
January 16, 2020
Filing Date:
June 12, 2019
Export Citation:
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Assignee:
ZAVLIARIS KONSTANTINOS (GR)
International Classes:
B32B5/02; B32B13/02; B32B13/04; B32B13/12; B32B13/14; B32B25/10; B32B27/12; B32B27/20
Foreign References:
US20060188674A12006-08-24
US20100273376A12010-10-28
EP3106277A12016-12-21
US3753849A1973-08-21
Attorney, Agent or Firm:
MASOULAS, Athanassios (GR)
Download PDF:
Claims:
CLAIMS

1. Multilayer millimeter thin Glass fiber high performance cement laminate film made up of top and bottom high performance polymer modified cement matrixes with very fine aggregates, interfaces of Polymer grouts with ultra fine silica fume and Glass Fiber Mats or Meshes. The grout penetrates the Glass fiber Mat or Mesh incorporated in the interfaces. The film is used as floor or wall cover replacing tiles, as decorative element or as constitutive element of composite laminated film (claim 2), closed composite Elements (claims 3, 4, 5, 6) or Sandwich Elements (claims 7,8,9,10).

2. Composite Laminated Elements made of individual multilayer films of claim 1 bonded together by interfacial grout and inorganic polymer modified bonding mortar. The composite Laminated Elements are used as decorative or structural Elements or for manufacture of furniture or as elements for security of buildings and installations against intrusion, or for manufacture of boxes.

3. Linear or two-dimensional Closed Composite Elements used as decorative or structural Elements or for manufacture of furniture or as elements for security of buildings and installations against intrusion or for manufacture of boxes, made of one or more multilayer films of claim 1 wrapped around core of Expanded Polystyrene with grooves for mechanical interlocking of the interfacial grout and glued onto its lateral surfaces by interfacial grout and inorganic polymer modified inorganic bonding mortar, under pressure.

4. Linear or two-dimensional Closed Composite Elements of claim 3, made of one or more multilayer films of claim 1 wrapped around core of lightweight Pumice Concrete with grooves for mechanical interlocking of the interfacial grout and glued onto its lateral surfaces by interfacial grout and polymer modified inorganic bonding mortar, under pressure.

5. Linear or two-dimensional Closed Composite Elements of claim 3, made of one or more multilayer films of claim 1 wrapped around core of lightweight Perlite Concrete with grooves for mechanical interlocking of the interfacial grout and glued onto its lateral surfaces by interfacial grout and polymer modified inorganic bonding mortar, under pressure.

6. Linear or two-dimensional Closed Composite Elements of claim 3, made of one or more multilayer films of claim 1 wrapped around core of lightweight Cellular Concrete with grooves for mechanical interlocking of the interfacial grout and glued onto its lateral surfaces by interfacial grout and polymer modified inorganic bonding mortar, under pressure.

7. Linear or two-dimensional Sandwich Elements used as decorative or structural Elements or for manufacture of furniture or as elements for security of buildings and installations against intrusion, or for manufacture of boxes, made of one or more multilayer films of claim 1 bonded on bottom and top of core of Expanded Polystyrene with grooves for mechanical interlocking of the interfacial grout and glued onto its lateral surfaces by interfacial grout and polymer modified inorganic bonding mortar, under pressure.

8. Linear or two-dimensional Sandwich Elements of claim 7 made of one or more multilayer films of claim 1 bonded on bottom and top of core of Lightweight Pumice Concrete with grooves for mechanical interlocking of the interfacial grout and glued onto its lateral surfaces by interfacial grout and polymer modified inorganic bonding mortar, under pressure.

9. Linear or two-dimensional Sandwich Elements of claim 7 made of one or more multilayer films of claim 1 bonded on bottom and top of core of Lightweight Perlite Concrete with grooves for mechanical interlocking of the interfacial grout and glued onto its lateral surfaces by interfacial grout and polymer modified inorganic bonding mortar, under pressure.

10. Linear or two-dimensional Sandwich Elements of claim 7 made of one or more multilayer films of claim 1 bonded on bottom and top of core of Lightweight Cellular Concrete with grooves for mechanical interlocking of the interfacial grout and glued onto its lateral surfaces by interfacial grout and polymer modified inorganic bonding mortar, under pressure.

Description:
ULTRA THIN, LESS THAN lmm, MULTILAYER LAMINATES MADE UP OF HIGH PERFORMANCE POLYMER MODIFIED

CEMENT MORTAR

GENERAL

The Present Invention refers to ultrathin (0.80-3.00mm) multilayer film of large size (width up to 3.00m x length over 10.00m). The film is made of more than one layers, Fig.1/5, Layers 1.1.1 , 1.1.2, 1.1.3, 1.1.4, 1.1.5, bonded together monolithically. They are 2 layers of high performance cement matrix, layers 1.1.1 and 1.1.2 incorporating the Glass Fiber layer 1.1.5 and two glue interfaces 1.1.3 and 1.1.4 penetrating the Glass fiber layer and glueing it to cement matrixes.

THE STA TE OF THE ART So far the laminates are composed of fibers of different types and materials (glass - carbon - polymers - metals) in (a) polymer or (b) metallic matrix. There are also inorganic laminates of inorganic fibers (mostly Glass Fibers) in inorganic matrices (c), used mainly in repairing concrete or stonewall elements made by projection or patching of the matrix into the element to repair with thickness several times higher than that of the present invention and lower strength.

The drawbacks of (a) laminates are low strength and high deformability at elevated temperatures and high cost. The drawback of (b) laminates is the high cost, whereas laminates (c) are thick and with low strength as a result on the one hand of the low strength of the cement mortars projected or cast in contact with the elements under repair and on the other due to inability of the mortar to penetrate the glass fiber bundles (usually involving 100 - 200 individual fibers), thus the bonding surface between fibers and matrix is the outer surface of the bundle instead of the sum of the outer surfaces of all the fibers of the bundle which would be many times larger.

SHORT DESCRIPTION OF THE INVENTION - ADVANTAGES

According to present invention the multilayer film is made up of the following layers, ref. to Fig.1/5: a. The bottom matrix (1.1.1)

b. The top matrix (1.1.2),

both fraction of millimeter thin, from high performance cement grout with very fine aggregates, 10 microns in size, modified by the polymers which constitute the two interfaces

c. The interfaces, one ( 1.1.3), on top of the lower matrix and the other (1.1.4), beneath the upper matrix. The interfaces are grout made up of two polymers and ultrafme, (0.1 micron = 1/10000 of mm), thin silica fume. These interfaces secure the monolithical bond between Glass Fibers and matrixes.

d. The Glass fiber layer (1.1.5) in form of mats or meshes with 300 - 450gr/m 2 and strength as illustrated in Table 3. This layer is penetrated by the polymer grout and is the main load bearing component of the multilayer film.

Because the space between the individual fibers is 3-5 micron whereas the size of the particles of the interfacial grouts is 0,1 micron, the grouts benetrate the fibers resulting m this way m high bond between the fibers and the top and bottom matrixes.

In addition, the polymers of the interfacial grout are also constitutive materials of the matrixes. In this way continuance of the film is achieved (i.e. monolithical structure made up of the penetrated Glass Fiber Layer, the interfaces and the top and bottom matrixes).

The result is high strength and stiffness of the film at low cost in comparison with the existing films and higher thermal resistance and environmental friendly character due to inorganic materials, which represent more than 90% of the mass of the present cement laminate. In the case of loads applied to the film higher than the ultimate Load of the individual film described so far, the following alternatives can be utilized:

I. Individual multilayer film with more than one Glass fiber layer on top of each other in the form of Glass Fiber Mesh which are bonded together monolithically by means of the interfacial grout

II. Composite laminated films made up of two or more individual multilayer films ref. Fig.2/5 where films 1.1., 1.2 are bonded together along the interface 1.3 in a two film laminates, and Figure 3/5 illustrating a four film laminate with individual films 1 ,2,3 ,4 with more than one glass fiber layer each, bonded together along the interfaces 5,6,7,

III. Closed composite elements made up of individual multilayer film wrapped around a lightweight core (usually of expanded polystyrene or lightweight pumice or perlite concrete or cellular concrete) and glued on the core by means of the aforementioned polymer grout.

IV. Sandwich components, made up of individual multilayer film bonded on the top and bottom of lightweight core by means of the polymer grout. DETAILED DESCRIPTION

The aforementioned structure of the multilayer film is composed of :

(I) Lower matrix 0,2-0, 8mm thick

(II) First interface 0, 1 -0,4mm thick

(III) Glass Fiber layer 0, 1 -0,3mm thick

(IV) Second inter face 0, 1 -0,4mm thick

(V) Upper matrix 0,3 -1 , 1 mm thick

The mix design of the two matrixes is illustrated in Table 1 , those of the interfaces bottom (1.1.3) and top (1.1.4) in Table 2. The properties of the Glass Fibers are shown in Table 3. The mix design of the interfaces (5), (6), (7) of Fig. 3/5 (closed Composite Element) are shown in Table 4.

The individual multilayer films of 1 ,00m x 2,00 m weighs l ,3-2,6kg/m 2 for thicknesses 1 ,0mm - 2.0mm respectively. In this way the handling of such a film or the manufacture of any other product made of it are very easy without need of any lifting equipment.

The composite laminated films are made by bonding individual films together with the mix of Table 4 under pressure. The number of the constitutive individual films is determined by the respective structural design, in order to satisfy the requirements on strength and stiffness.

The closed composite Elements, Fig.4/5, are made of individual multilayer films which are bonded on the external surface of lightweight core (2), of expanded Polystyrene or lightweight pumice or perlite, or cellular concrete, with mix design as in Table 5.

The non-slip bond between film and core is achieved by means of grooves (3) along with glueing across the interface (4), ref.Fig.4/5. This Fig 4/5 involves Figures 4.1 , 4.2, 4.3. Fig.4.1 illustrates the plan, Fig 4.2 the long- section and Fig 4.3 the cross section of this element.

The Sandwich Elements, Fig 5/5, are made of individual multilayer film bonded on top and bottom sides of lightweight core of lightweight pumice, or perlite, or cellular concrete as with mix design illustrated in Table 5 and thickness depended on the loads to be applied. The non-slip bond between film and core is achieved by combined action of mechanical interlocking in groves (3) and glueing along the interface (4) as illustrated in Fig.5.5. Fig.5.5 involves Figures 5.1, 5.2 and 5.3. The Fig. 5.1. illustrates the plan, Fig 5.2 the long section and Fig. 5.3 the cross section of the element.

When necessary the external surface of the films are painted by acrylic paints, refer Fig. 3/5 (8), (9).

USES The individual multilayer film, or closed composite elements, and sandwich (if this is required by the Loads to be applied or by the desired stiffness) elements can be used as structural, and decoration elements and as Elements of Security against Intrusion in Building. In more details:

- As Sandwich Elements of external walls

- As Sandwich Elements of internal walls

- As Floor and Wall cover replacing tiles, or in situ cast in - or outdoor screeds

- As Roof cover of anv form iesneciallv curved in sheds and canopies As decoration Element (sunbrakes, blinds, parapets, planters, fences and external walls)

- As structural Element of furniture, benches and countertops of batch and kitchen in - or outdoor and as shelves in bookcases - For packing - and transportation boxes, replacing carton boxes

- For planters of any type

- For the manufacture of saves (with fire resistance and isolation)

- In liquid containing structures

- As permanent shuttering of fair face concrete structures of any form, replacing traditional formwork materials, especially for curved Elements, where the formwork is difficult and costly or in the case of fast track projects

EXISTING SIMILAR MATERIALS Today material of similar usage are:

- Plywood, made up of veneered films 0,5-3.00mm thick and in some cases 8mm bonded together in cross directions of fibers in order to achieve uniform strength

- Aluminum and light metal sheets

- Gypsumboard and cement board with minimum thickness of 12,5mm and much lower strength in comparison with the present cement laminate films

- Polymer composites

- Metall composites

- SANDWICHES made up of above films bonded on lightweight core

PRODUCTION METHOD

A. The individual multilayer films are produced as follows:

A levelled working table larger than the film to be produced at least 300mm in each direction is the basis. On top of it a heating film (l-2mm thick with electrical resistances) controlled by thermostat is placed. This film provides uniform heating of 45-50 which is the optimum Temperature for the process. On top of this 0,80mm Aluminum film larger than the film to be produced by 50mm in each direction is placed. Onto the surface of this Aluminum film the multilayer film to be produced is marked and along the marking, paper strip with the same thickness as that of bottom matrix is placed. Then a second paper strip as thick as the rest of the film to be produced is placed 20mm retracted, on top of the first paper strip. In this way a causi mold is made into which the film will be cast. Then, the Aluminum film is placed on the top of the surface of the heating film which is already connected to A/C and a release agent containing wax or cutting oil coating is coated on the Aluminum sheet, enabling the striking off of the film without damage or matrix.

At the same time the constitutive materials of the matrix are mixed as follows: water-polymers (50% SBR Styrene Butadiene Rubber + 50% SAE, Styrene Acrylic Ester), mixing for 30 seconds - Addition of silica fume, mixing for 45 seconds - limestone powder, mixing for 75 seconds, addition of cement, mixing for 60 seconds. As soon as the mix is ready it is cast on top of Aluminum film and spread by means of wide spatula. The target thickness of 0,20 mm is achieved by an Aluminum bar moving along the film to be produced and guided by the bottom paper strip. Once the layer is completed the material is left for 10-15 minutes in order to get consistency allowing the movement and high pressure of roller. Then, the mix of the grout of the first interface is mixed as follows: and is applied by brush on top of the already cast bottom matrix with thickness of 0,10 - 0, 15mm (1 coarse). After this, the Glass Fiber mat is placed on top of the grout. The mat is pushed to be plounged into the interfacial grout by means of plastic roller with its small side protruding 50mm and is penetrated by the grout by means of a threaded Aluminum roller moving forwards only across the Glass fiber mat. Then the already mixed grout of the Second interface in cast on top of the Glass Fiber Mat. The second grout is mixed following the same process as the first one, Polymer (50% SBR + 50% SAE), mixing for 30 seconds - addition of silica fume, mixing for 45 seconds, and is pushed against the glass fiber mat by means of an Aluminum threaded roller moving along the mat. In this way a thickness of 0,25-0, 30mm of the two interfaces involving the Glass Fiber mat, is achieved. In the meantime the materials of the top matrix are mixed in a mixer with 300-500 rps/minute as follows: Water + Polymers (50% SBR - 50% SAE)

- mixing for 30 seconds - addition of silica fume - mixing for 45 seconds

- Addition of cement - mixing for 60 seconds - Addition of limestone powder - mixing for 75 seconds - addition of superplasticizer PE (Polycarbonilic Ether) - mixing for 45 seconds. This mix is cast on top of the second grout and is spread by means of Aluminum bar moving along the surface of the film guided by the second paper strip, achieving in this way the target thickness.

B. The composite laminated elements are produced as follows:

On the aforementioned Aluminum film which in this case functions as bottom of the mold and as Caliber and which is already placed on top of heating film the Element to be produced is marked.

Lateral shuttering of Aluminum, plastic of metal, as high as the element to be produced are fixed by mechanical means (double face self adhesive strips - fasteners - mechanical clamping) along the perimeter marked. Then the internal surface of shutterings are coated by release agent (max based or cutting oil).

After this, the Aluminum film is placed in between the shuttering on top of the heating film. Then, the first ready multilayer film is placed on top of Aluminum film and on top of it the glue of the first interface with thickness 0,3-0, 7mm is cast and spread by spatula and Aluminum bar moving across the whole surface. Then, the bottom of the second ready individual film is coated by the glue and the film is placed on top of the already cast glue of the first film. Finally, on top of the final ready film an at least 8mm thick glass pane is placed for 24 hours. The glass pane is removed after 24 hours and is transferred to the removal position for 3 days and then it can be used.

Table 1 : Mix Design of Top and Bottom Matrix

r. w : rai ls per weigm Table 2: Mix Design of Interfacial Grout

Table 3: Properties of Glass Fiber Mats and Meshes

Table 4: Mix design of Glue Mortar to Table 5 : Mix design of Pumice concrete - perlite concrete - Cellular concrete

C. The Closed Composite Elements are produced as follows:

The perimeter of the Element to be produced is marked on the aforementioned Aluminum Film which is placed on top of the heating film. Then, the lateral shutterings with staggered section made of Aluminum, plastic or metal are placed on the perimeter marked and fixed mechanically by means of double face self adhesive strips- fasteners - mechanical clamping. After this, the internal surface of the shutterings is coated by release agent (based on wax or cutting oil) and the heating film is connected to A/C. After this, the ready multilayer film at minimum age 3 days is placed on top of the Aluminum film and the bottom interfacial grout 0,3-0, 7mm thick is cast on top of this film and spread by Aluminum bar guided by the staggered lateral shutterings. Then, the external surfaces of the core treated as per Fig.4/5 and grooves at the interfacial levels of core are coated with the interfacial grout and the core is placed within the folded multilayer film. Then, follows the bending of the long sides along the corresponding lines where the initial thickness is reduced to 2/3 and it is followed by bending of shorter sides both along the corresponding lines where the thickness of the film is reduced to 2/3 of the initial in order to facilitate its bending and pushed in contact with the top side of the core and the whole element is placed within the shuttering. Finally a 12mm glass pane of equal size as the element to be produced is placed on top of the film which is removed after 24 hours, and the product is transferred to curing space for 3 days after which it can be used.

D. The Sandwich element are produced in the following way: The perimeter of the Sandwich element to be produced is marked on the Aluminum film which is placed on top of the heating film.

After this, Aluminum of Plastic or metal lateral shutterings with staggered section, ath the levels of the first and the second interface as high as the sandwich element to be produced are placed on the marked perimeter and fixed mechanically (by double face self-adhesive strips - fasteners or mechanical clamping) in place. It follows the coating of the internal surfaces of the lateral shuttering by release agent (based on wax or cutting oil) and the heating film is connected to A/C.

Then, the bottom ready multilayer film at a minimum age of 3 days is placed on top of the Aluminum film and the bottom interfacial grout is 0,3- 0,7mm thick cast on top of the ready film and spread by Aluminum bar moving across its surface and guided by the lateral shutterings at the corresponding levels.

Then, the bottom and top surfaces of the core formed as per Fig.5/5 are coated by the interfacial grout and the core is placed on top of the bottom grout cast.

After this, the bottom surface of the top multilayer film is coated by the interfacial grout and placed on top of the core the top side of which is already coated by the same grout. Then, the whole system is placed within the lateral shutterings, and finally a 12mm glass pane of the same size as the sandwich Element to be produced is placed on top of the sandwich element. The glass pane is removed after 24 hours, and the product is transferred to curing area where it is kept for 3 days after which can be used.