AU2012100407A4 - Structural wall system incorporating recycled waste materials - Google Patents
Structural wall system incorporating recycled waste materialsInfo
- Publication number
- AU2012100407A4 AU2012100407A4 AU2012100407A AU2012100407A AU2012100407A4 AU 2012100407 A4 AU2012100407 A4 AU 2012100407A4 AU 2012100407 A AU2012100407 A AU 2012100407A AU 2012100407 A AU2012100407 A AU 2012100407A AU 2012100407 A4 AU2012100407 A4 AU 2012100407A4
- Authority
- AU
- Australia
- Prior art keywords
- structural
- wall system
- structural wall
- building board
- waste materials
- 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.)
- Ceased
Links
- 239000002699 waste material Substances 0.000 title description 6
- 238000000034 method Methods 0.000 abstract description 13
- 239000002131 composite material Substances 0.000 abstract description 7
- 238000010276 construction Methods 0.000 abstract description 5
- 239000000835 fiber Substances 0.000 abstract description 5
- 239000011173 biocomposite Substances 0.000 abstract description 4
- 239000000463 material Substances 0.000 abstract description 4
- 239000010893 paper waste Substances 0.000 abstract description 4
- 239000004033 plastic Substances 0.000 abstract description 4
- 229920003023 plastic Polymers 0.000 abstract description 4
- 238000004064 recycling Methods 0.000 abstract description 4
- 239000000853 adhesive Substances 0.000 description 8
- 230000001070 adhesive effect Effects 0.000 description 8
- 239000000203 mixture Substances 0.000 description 8
- 229920005989 resin Polymers 0.000 description 7
- 239000011347 resin Substances 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 5
- 238000002156 mixing Methods 0.000 description 5
- 239000004615 ingredient Substances 0.000 description 4
- 238000009413 insulation Methods 0.000 description 4
- 230000003014 reinforcing effect Effects 0.000 description 4
- 229920003043 Cellulose fiber Polymers 0.000 description 3
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 3
- 235000010469 Glycine max Nutrition 0.000 description 3
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 2
- 241000238631 Hexapoda Species 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 2
- 238000005253 cladding Methods 0.000 description 2
- 239000000123 paper Substances 0.000 description 2
- 229920001568 phenolic resin Polymers 0.000 description 2
- GHMLBKRAJCXXBS-UHFFFAOYSA-N resorcinol Chemical compound OC1=CC=CC(O)=C1 GHMLBKRAJCXXBS-UHFFFAOYSA-N 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 238000004078 waterproofing Methods 0.000 description 2
- 241000609240 Ambelania acida Species 0.000 description 1
- 235000017166 Bambusa arundinacea Nutrition 0.000 description 1
- 235000017491 Bambusa tulda Nutrition 0.000 description 1
- 244000025254 Cannabis sativa Species 0.000 description 1
- 235000008697 Cannabis sativa Nutrition 0.000 description 1
- 244000068988 Glycine max Species 0.000 description 1
- 244000082204 Phyllostachys viridis Species 0.000 description 1
- 235000015334 Phyllostachys viridis Nutrition 0.000 description 1
- 240000000111 Saccharum officinarum Species 0.000 description 1
- 235000007201 Saccharum officinarum Nutrition 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000004378 air conditioning Methods 0.000 description 1
- 239000010905 bagasse Substances 0.000 description 1
- 239000011425 bamboo Substances 0.000 description 1
- 239000010953 base metal Substances 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 1
- 239000004327 boric acid Substances 0.000 description 1
- 239000011449 brick Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 239000012895 dilution Substances 0.000 description 1
- 238000010790 dilution Methods 0.000 description 1
- 230000003467 diminishing effect Effects 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 239000003112 inhibitor Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000003032 molecular docking Methods 0.000 description 1
- -1 newsprint Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 238000009428 plumbing Methods 0.000 description 1
- 239000011120 plywood Substances 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000010802 sludge Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
Landscapes
- Dry Formation Of Fiberboard And The Like (AREA)
Abstract
Abstract This inventions details a method for recycling various materials such as natural organic fibre, waste paper & plastic bottles into a commercially viable composite & bio-composite corrugated building board incorporated into a structural wall system for use in residential & commercial construction.
Description
1 Australia Patents Act 1990 Complete Specification Innovation Patent Structural Wall System Incorporating Recycled Waste Materials The following statement is a full description of this innovation including the best method of manufacture known to me This invention in the first aspect details a method for recycling various products such as natural organic fibre, waste paper & plastic bottles into a commercially viable composite & bio-composite corrugated building board. The second aspect details the intended application of the invention in a structural wall system for use in residential & commercial construction.
2 Background of the invention The Building Industry has been reliant on timber products for many years for both structural & aesthetic purposes and although regrowth forests provide a sustainable alternative, diminishing resources are always increasing the cost of this raw material. This innovation reduces the reliance on sawn timber in the building industry by offering an alternative to timber framed walls whilst recycling waste materials thereby reducing land fill. Many composite building boards are commercially available & vary in composition in accordance to their designated purpose or intended use. Whilst our composite building board may share similar ingredients, process of manufacture &/or attributes of previous patents this invention is distinctive in both design form & integration into a structural system along with the benefits of utilising both waste & sustainable crop products for manufacture.
3 Summary of the invention A bio-composite building board comprising waste agricultural fibres including sugar cane bagasse, bamboo & Industrial Hemp Shiv (Cannabis sativa) but not limited to these to be used as cellulosic reinforcing fibre for the invention. A composite building board comprising waste paper, newsprint, cardboard & paper mill sludge, but not limited to these to be used as cellulosic reinforcing fibre for the invention. A composite building board containing a blend of some or all of the previously stated reinforcing fibres & also containing other minor ingredients for fire retardant purposes, insect treatment, mould inhibitor, waterproofing, flexibility & structural integrity. A resin to bind reinforcing fibres comprising a class 1 waterproof PVA, a soybean based thermo-setting resin, an A-bond phenol formaldehyde resin or a combination of these and other commercially.available adhesives suitable to meet either structural or non-structural application as required. A method of manufacture to blend, form & cure the invented structural building board to the desired corrugated shape & dimensions specifically intended for the purpose of incorporating as an integral structural member into our structural system but not limited to this application. A description of the invented structural system including all members & erection process of the application suitable for internal & external walls in residential & commercial construction but not limited to this application. A variation on the invented structural building board suitable for numerous uses in other construction methods. (20mm version for formply, roof insulation?, between floor joist for floor insulation, sandwich panel floor systems, etc). Advantages of the invention are to decrease the reliance on timber products in the building industry, reuse waste products where available, provide a recycled product as alternatives for a number of plywood & insulation products currently in use & to provide a modular system to the building industry decreasing transport costs & reducing build times.
4 Detailed description Invention aspect one detailing a method for recycling various products such as natural organic fibre, waste paper & plastic bottles into a commercially viable composite & bio-composite corrugated building board. [0001] Selection of cellulose fibres can be from a variety of sources both natural & recycled these fibres are best mulched or shredded to a size 0.5mm-1.5mm in thickness & 5mm-25mm in length then screened to be cleaned of dust & impurities. Recycled PET & HDPE from shredded plastic bottles can be added for increased flexibility of finished product (non-structural use only). [0002] Resin selection for a building board requiring structural certification & that sets permanently under controlled heat & pressure & will not deteriorate under wet conditions, heat or cold should be a (PF) phenol formaldehyde resin but recent innovations with soy based resins have been tested to achieve similar results with formaldehyde free adhesives. [0003] Resin selection for a non-structural board can be a number of type 1 cross linking PVA products suitable for long-term exposed applications (non structural) available on the market. [0004] This invention requires both types for structural & non-structural applications & both building boards are designed to meet similar classification in terms of density 600-680kg/m, bending strength modulus of elasticity 2500-3500mpa, internal bond strength 0.35-0.75mpa & a screw holding capacity in the range of 300-600N. [0005] Blending of selected ingredients with PVA should be done as follows in a batch mixer suitable for fibrous solutions - mix resin first, measure by weight of required batch quantity 50% water & 24% adhesive, blend together at a low speed for 10 min until consistent add 1% Boric acid for insect treatment, fire retarder & waterproofing purposes & continue to blend for another 10min at a low speed then add 25% by dry weight of the selected cellulose fibres by slowly adding the dry fibres whilst rotating & continue to blend until all fibres appear sufficiently moistened with no dry clumps & no free liquid. This may take some time (approx. 10-15min depending on quantity ) & include manually removing clumps from edges of mixing apparatus. After mixing allow to stand for 1-5 min to allow proper absorption of adhesive into cellulose material. [0006] Blending the cellulose fibres with PF resin such as Resorcinol or Soy based adhesives like Purebond should be done in a similar manner excluding the water. Manufacturers directions should be followed regarding any dilution of adhesive to remain inside the limitations of manufacturers warranty with enough adhesive blended into the mixture to create the same sufficiently moistened result.
5 [0007] After blending of ingredients & sufficient rest time for absorption has passed the mixture is laid out on molds specially designed to form the desired corrugated form required for structural integrity. Protective paper can be used top & bottom to protect both material & machinery. Mixture is then gradually pressed to remove moisture up to 50OOkpa as required for particular adhesives & heat pressed to 150 180 degrees celsius for 1-5 minutes. [0008] Cured boards are stacked flat & allowed to air dry & cure completely before being checked for size & density then docked to desired length and packaged ready for delivery. [0009] Another method for mass production of a continuous length of corrugated building board involves a conveyor system with heated rollers applying an increasing pressure to form & cure the mixture simultaneously. This method would require docking to preset lengths as part of an automated process.
6 Invention aspect two details the intended application of the invention in a structural wall system for use in residential & commercial construction. [0010] The invented structural wall system consists of a light gauge.metal 0.6mm 1mm U-shaped base channel with dimensions of 50mm high & a width of 70mm to receive the corrugated building board. Lengths are 2400mm-6000mm & are cut to exact length on site as required. End & corner receiver channels are of a similar material. Head or top channel requires more strength & has a base metal thickness of 1.5mm-2mm this top channel is supported entirely by the invented corrugated building board. [0011] Installation methods can include fixing all bottom channels first then corrugated building board then top channel for each wall section or by assembling each section on the ground & standing in tilt-up fashion before fixing in place. Wall sections will brace in one direction due to their structural integrity but require bracing support across the wall until all walls have been fixed in place. Cross winds have to be allowed for during this standing process. [0012] Top channels require extra support beside larger openings to carry beams or lintels as required supporting upper floor or roof loads. The required number of timber studs or steel columns are fixed in place for this purpose. Openings are fully framed in a similar fashion providing fixing members for windows & doors. [0013] Tie-down of external wall structure & internal bracing walls is achieved using conventional fixing methods & full length rods as per relevant wind ratings & engineers design in accordance with the building code of Australia. Special wall ties are required at T-junctions, openings & corners to resist lateral movement at middle of panels. [0014] All electrical, data, plumbing & most air-conditioning services can be run within the corrugations as required before external sarking, sisalation &/or insulation is completed. Building board can be drilled easily for penetrations & still retain integrity (conditions apply). [0015] External brickwork & cladding can be fixed in accordance to manufacturers recommendations including brick ties. Specialist cladding can also be fixed from inside to reduce finishing time.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2012100407A AU2012100407A4 (en) | 2012-04-16 | 2012-04-16 | Structural wall system incorporating recycled waste materials |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2012100407A AU2012100407A4 (en) | 2012-04-16 | 2012-04-16 | Structural wall system incorporating recycled waste materials |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| AU2012100407A4 true AU2012100407A4 (en) | 2012-06-21 |
Family
ID=46489070
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU2012100407A Ceased AU2012100407A4 (en) | 2012-04-16 | 2012-04-16 | Structural wall system incorporating recycled waste materials |
Country Status (1)
| Country | Link |
|---|---|
| AU (1) | AU2012100407A4 (en) |
-
2012
- 2012-04-16 AU AU2012100407A patent/AU2012100407A4/en not_active Ceased
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| AMFD | Amendment of filing date |
Effective date: 20120416 |
|
| FGI | Letters patent sealed or granted (innovation patent) | ||
| MK22 | Patent ceased section 143a(d), or expired - non payment of renewal fee or expiry |