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GB2486045A - Cellulose fibre and straw panel - Google Patents

Cellulose fibre and straw panel Download PDF

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Publication number
GB2486045A
GB2486045A GB1117849.8A GB201117849A GB2486045A GB 2486045 A GB2486045 A GB 2486045A GB 201117849 A GB201117849 A GB 201117849A GB 2486045 A GB2486045 A GB 2486045A
Authority
GB
United Kingdom
Prior art keywords
panel
panel according
straw
binding mixture
material comprises
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.)
Granted
Application number
GB1117849.8A
Other versions
GB2486045B (en
GB201117849D0 (en
Inventor
Glenn Williams
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
Publication of GB201117849D0 publication Critical patent/GB201117849D0/en
Publication of GB2486045A publication Critical patent/GB2486045A/en
Application granted granted Critical
Publication of GB2486045B publication Critical patent/GB2486045B/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/16—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of fibres, chips, vegetable stems, or the like
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • E04C2/243—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 one at least of the material being insulating
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B32B2262/065—Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/08—Animal fibres, e.g. hair, wool, silk
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)
  • Building Environments (AREA)

Abstract

A panel (101) for providing a surface comprises a core sheet of composite material. The composite material comprises a self-binding mixture of cellulose fibres and water, and a second material comprising straw. The straw may be wheat straw. The panel may comprise additional materials including hemp, wool, hair fiber, gypsum, cement, aerogel, expanded polystyrene and an anti-microbial additive which may be a silver compound. The sheet may be laminated with melamine laminas. The sheet may be sculpted to provide a surface finish. Also provided is a method of creating a composite material by obtaining a self binding mixture of cellulose fibers and water, obtaining a second material comprising straw and mixing the self binding mixture with the second material to create a homogenous mass which can be formed. The self binding mixture may be in granulate form, the mixing step may comprise spraying the self binding mixture onto particles of the second material.

Description

I
A Panel
Technical Field
The present invention relates to a panel for providing a surface and a method of creating a composite material suitable for manufacturing a panel.
Background of the Invention
Panels can be used to provide a surface to a wall, floor, ceiling or other fixture, in domestic, commercial, industrial and public buildings.
However, the core sheet of such panels is not always made from an environmentally friendly or sustainable material.
Brief Summary of the Invention
According to a first aspect of the invention there is provided a panel according to claim 1.
IS According to a second aspect of the invention there is provided a method of creating a composite material according to claim 15.
* Brief Description of the Several Views of the Drawings Figure 1 shows a rectangular panel; Figure 2 is a cross section through the panel shown in Figure 1; and Figure 3 shows a flow chart outlining steps taken to manufacture the **.
panel shown in Figure 1.
Description of the Best Mode for Carrying out the Invention Figures 1 and 2 A rectangular panel 101 is shown in Figure 1 and a cross-section through panel 101 is shown in Figure 2. Panel 101 comprises a core sheet 201 of composite material, which has two parallel large faces 202 and 203. It also has four narrow edge faces (not shown). A lamina 204 is adhered to large face 202 with a layer of adhesive 205, and a lamina 206 is adhered to large face 203 with a layer of adhesive 207.
Typically, although not shown, edge strips would be bonded to the edge faces, thus covering the whole of the core sheet The core sheet is made from a composite material that is a mix of a self-binding mixture of cellulose and water with another material, as will be described with reference to Figure 3.
The material of the lamina may be vinyl paper, foil, melamine, high pressure laminates, or any other suitable laminate material. The lamina may be adhered by a method such as described in United Kingdom Patent Publication No. 2 447 896. Alternatively, it may be applied in a vacuum wrapping and/or pressing process at a controlled temperature.
Figure 3 The method of manufacturing core sheet 201 is described in Figure 3.
* :° First, at step 301, a self-binding mixture of cellulose and water is obtained. The cellulose is typically in dry granulate form but may be in setS another form. This material may be of a type that is currently available, for example from Zelfo Technology SAS, and which is self-binding due to naturally occurring binding agents, rather than, for example, synthetic polymers.
The cellulose contains fibres or residual materials used from the plant processing industries, for example jute, hemp, sisal, waste paper, and so on.
The fibres are chopped finely and dried, then ground and mixed with water in a refiner using optional natural additives. Alternatively, the cellulose may be obtained from another source and the mixture may be produced in another way.
At step 302, a second material is obtained. This second material may comprise, either singularly or in combination, straw, hemp, wool (such as but not limited to sheep's wool, rock wool and wood wool), wood fibre, hair fibre, recycled gypsum, cement, or other natural, vegetable or organic materials.
Materials that provide a degree of insulation may be used, such as aerogel (silica or otherwise), expanded polystyrene, and so on.. This second material is also typically in dry granulate form but may be in another form. In embodiments comprising straw, the straw may be of various types, but in a preferred embodiment the second material comprises wheat straw. in one preferred embodiment, the second material comprises straw and aerogel.
At step 303 the self-binding mixture (of cellulose and water) and the second material are mixed together to create a hornogenous mass. in one such mixing process, batches of the second material are mixed with the self binding mixture by spraying. That is, the self-binding mixture is formed into a ** ,,j spray using compressed air in an atomising head, and the spray is directed * : t onto the batch of the second material. Where the second material comprises more than one component, such as wheat particles and aerogel particles, the two or more particle types are mixed together in a dry state prior to mixing with the self-binding mixture in the spraying process.
::: Optionally, an anti-microbial additive, such as a silver additive, may be * added during this mixing stage in order to create a material that is resistant to microbe growth. By mixing the anti-microbial additive into the mixture at this stage allows the additive to be distributed throughout the bulk of the finished material The mixture is then processed to produce the required shape in a process comprising moulding, forming or pressing, which may involve application of pressure, part-or pre-drying, and reshaping or casting. Thus, to form a panel, at step 304 a flat continuous sheet of composite material is produced by continual pressing, slow cooling and drying. At step 305, once cooled and dried, this sheet is cut to produce one or more core sheets of the required size or sizes.
At step 306 a surface finish is applied to one or more large faces of a core sheet. This may be done by routering out the core sheet to various depths and smoothing the newly exposed core material. It may also or alternatively include a spray application of a material such as polyurethane or water based lacquers or solid colours, or powdercoat applications.
At step 307 laminas and edge strips are applied if required to complete each panel.
The choice of second material to create a core sheet imparts different characteristics to the composite material. Use of insulating material such hemp, wool, hair fibre and aerogel wilt produce a material with high heat insulation properties. A panel made from such a core sheet will reduce the amount of heat loss while being thinner than typical insulating panels.
Use of recycled gypsum or cement will produce a highly durable material with significant impact resistance, while recycled gypsum will also impart fire-resistant qualities.
Other second materials are also envisaged that will provide similar or other characteristics to a composite material. Although very suitable for making panels, the material may also be used to form other articles.

Claims (6)

  1. Claims 1. A panel for providing a surface, comprising: a core sheet made of a composite material, said composite material comprising a self-binding mixture comprising cellulose fibres and water, and a second material comprising straw.
  2. 2. A panel according to claim 1, wherein said straw comprises wheat straw.
  3. 3. A panel according to claim 1 or claim 2, wherein said second material comprises hemp
  4. 4. A panel according to any one of claims I to 3, wherein said second material comprises wool.
  5. 5. A panel according to any one of claims I to 4, wherein said second material comprises hair fibre. * S..
  6. 6. A panel according to any one of claims I to 5, wherein said second material comprises gypsum. 5sSS *SS7. A panel according to any one of claims 1 to 6, wherein said second material comprises cement.B. A panel according to any one of claims 1 to 7, wherein said second material comprises aerogel.9. A panel according to any one of claims I to 8, wherein said second material comprises expanded polystyrene.10. A panel according to any of claims 1 to 9, wherein said core material further comprises an anti-microbial additive.11. A panel according to any of claims I to 10, wherein said anti-microbial additive comprises a silver compound.12. A panel according to any of claims 1 to 11, wherein said core sheet has two opposing large faces, and further comprising a pair of laminas, each bonded to one large face of said core sheet.13. A panel according to claim 12, wherein said laminas comprise melamine laminas. 0 * * . S14. A panel according to any of claims Ito 13, wherein at least one face of said core sheet is sculpted to provide a surface finish. S. StS me..15. A method of creating a composite material suitable for use in a S...panel, comprising: * obtaining a self-binding mixture of cellulose fibres and water; obtaining a second material comprising straw; mixing said self-binding mixture with said second material to create a homogenous mass; and forming said mass.16. A method according to claim 15, wherein said straw is wheat straw.17. A method according to claim 15 or claim 16, wherein said second material comprises hemp.18. A method according to any one of claims 15 to 171 wherein said second material comprises wool.19. A method according to any one of claims 15 to 18, wherein said second material comprises hair fibre.20. A method according to any one of claims 15 to 19, wherein said second material comprises gypsum.* 21. A method according to any one of claims 15 to 20, wherein said second material comprises cement. S...° 20 22. A method according to any one of claims 15 to 21, wherein said second material comprises aerogel. *5. S...23. A method according to any one of claims 15 to 22, wherein saki second material is expanded polystyrene.24. A method according to any of claims 15 to 23, wherein said core material further comprises an antimicrobial additive.25. A method according to any of claims 15 to 23, wherein said core material further comprises an antimicrobial silver additive.26. A method according to any of claims 15 to 25, wherein said self-binding mixture is obtained in granulate form.27. A method according to any one of claims 15 to 26, wherein said mixing step comprises spraying said seff-binding mixture onto particles of said second material.26. A method according to claim 27, wherein particles of a first component are mixed with particles of a second component in a dry state to produce said second material before said second material is sprayed by said self-binding mixture. e. * * * * * * S S...S 0.*. S...S *S
GB1117849.8A 2010-10-15 2011-10-14 Cellulose fibre and straw panel Expired - Fee Related GB2486045B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB1017495.1A GB2484545A (en) 2010-10-15 2010-10-15 Panel comprising sustainable material

Publications (3)

Publication Number Publication Date
GB201117849D0 GB201117849D0 (en) 2011-11-30
GB2486045A true GB2486045A (en) 2012-06-06
GB2486045B GB2486045B (en) 2017-01-04

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Family Applications (2)

Application Number Title Priority Date Filing Date
GB1017495.1A Withdrawn GB2484545A (en) 2010-10-15 2010-10-15 Panel comprising sustainable material
GB1117849.8A Expired - Fee Related GB2486045B (en) 2010-10-15 2011-10-14 Cellulose fibre and straw panel

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Application Number Title Priority Date Filing Date
GB1017495.1A Withdrawn GB2484545A (en) 2010-10-15 2010-10-15 Panel comprising sustainable material

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Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113107135B (en) * 2021-04-08 2022-09-16 中成进出口股份有限公司 Environment-friendly building board based on degradable composite material

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0556577A1 (en) * 1992-01-20 1993-08-25 Ludwig Krickl Molded article containing cellulose and process for obtaining the same
DE4402244A1 (en) * 1994-01-26 1995-07-27 Asfil Isolations & Filtermater Sound and heat insulating material
WO2002059212A1 (en) * 2001-01-23 2002-08-01 Amylum Europe N.V. Method for preparing composite materials containing natural binders
GB2452235A (en) * 2007-03-05 2009-03-04 Eco Mats Ltd Plant fibre mat and method of making a plant fibre mat
WO2010114646A1 (en) * 2009-03-30 2010-10-07 United States Gypsum Company (Large Entity) Panels including renewable components and methods for manufacturing same

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB151808A (en) * 1919-09-02 1920-10-07 Alfred Blundell Slabs, blocks and the like building and paving units
FR2041702A6 (en) * 1969-05-05 1971-02-05 Thevenot Christian Hydroxy methyl cellulose control in plaster - contg vermiculite etc for building panels
JP2001287979A (en) * 2000-02-02 2001-10-16 Okumoto Seifun Kk Building material composition utilizing wheat bran
US20030060113A1 (en) * 2001-09-20 2003-03-27 Christie Peter A. Thermo formable acoustical panel
US6902797B2 (en) * 2002-11-12 2005-06-07 Innovative Construction And Building Materials Gypsum-based composite materials reinforced by cellulose ethers
WO2007053852A2 (en) * 2005-11-01 2007-05-10 E. Khashoggi Industries, Llc Cementitious composites having wood-like properties and methods of manufacture
ES2345804B1 (en) * 2009-03-31 2011-07-29 Jordi Castañe Callis LOW DENSITY ARGAMASE WITH THERMO-ACOUSTIC PROPERTIES.
US20110271616A1 (en) * 2010-04-16 2011-11-10 E2E Materials Naturally sourced building materials

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0556577A1 (en) * 1992-01-20 1993-08-25 Ludwig Krickl Molded article containing cellulose and process for obtaining the same
DE4402244A1 (en) * 1994-01-26 1995-07-27 Asfil Isolations & Filtermater Sound and heat insulating material
WO2002059212A1 (en) * 2001-01-23 2002-08-01 Amylum Europe N.V. Method for preparing composite materials containing natural binders
GB2452235A (en) * 2007-03-05 2009-03-04 Eco Mats Ltd Plant fibre mat and method of making a plant fibre mat
WO2010114646A1 (en) * 2009-03-30 2010-10-07 United States Gypsum Company (Large Entity) Panels including renewable components and methods for manufacturing same

Also Published As

Publication number Publication date
GB2486045B (en) 2017-01-04
GB2484545A (en) 2012-04-18
GB201017495D0 (en) 2010-12-01
GB201117849D0 (en) 2011-11-30

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Date Code Title Description
PCNP Patent ceased through non-payment of renewal fee

Effective date: 20170404