WO2011039538A1 - Building composition and recyclable building and packaging components formed therefrom - Google Patents

Building composition and recyclable building and packaging components formed therefrom Download PDF

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Publication number
WO2011039538A1
WO2011039538A1 PCT/GB2010/051628 GB2010051628W WO2011039538A1 WO 2011039538 A1 WO2011039538 A1 WO 2011039538A1 GB 2010051628 W GB2010051628 W GB 2010051628W WO 2011039538 A1 WO2011039538 A1 WO 2011039538A1
Authority
WO
WIPO (PCT)
Prior art keywords
building
composition according
beads
binder
composition
Prior art date
Application number
PCT/GB2010/051628
Other languages
French (fr)
Inventor
Robert John Smith
Thomas Frederick Smith
David Arthur Hanley
David Lathwell
Original Assignee
Sign Evolution Limited
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 Sign Evolution Limited filed Critical Sign Evolution Limited
Publication of WO2011039538A1 publication Critical patent/WO2011039538A1/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/28—Polysaccharides or derivatives thereof
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J11/00—Recovery or working-up of waste materials
    • C08J11/04—Recovery or working-up of waste materials of polymers
    • C08J11/06—Recovery or working-up of waste materials of polymers without chemical reactions
    • C08J11/08—Recovery or working-up of waste materials of polymers without chemical reactions using selective solvents for polymer components
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/7604—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only fillings for cavity walls
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/7608—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising a prefabricated insulating layer, disposed between two other layers or panels
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00034—Physico-chemical characteristics of the mixtures
    • C04B2111/00137—Injection moldable mixtures
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00663—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like
    • C04B2111/00698—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like for cavity walls

Definitions

  • This invention relates to a building composition, for example for form- ing structural and decorative components, and in particular to materials which can be readily recycled for re-use when the building is no longer required.
  • the composition can also be used to form packaging.
  • the hardened composition is readily recyclable.
  • waste and recycled materials as a filler for building materials is well-known.
  • power station ash has been used for the manufacture of building blocks
  • recycled glass particles have also been used in building products.
  • the binder used for these types of product has been cement-based or, more recently, resin-based. While these have proved generally satisfactory for some construction uses, they present a problem when the building is altered or demolished, because they typically require high-powered crushing machines to reduce the blocks and other components to particles for re-use or disposal.
  • Cavity wall insulation introduced into existing cavity walls is typically in the form of expanded plastics beads, for example polystyrene beads, which are carried into the cavity from a suitable injection point by a current of air.
  • expanded plastics beads for example polystyrene beads
  • This enables the cavity to be filled from a relatively small number of injection points, minimising disruption to the building during the operation.
  • this method does afford a significant improvement in the insulative properties of the walls, it does have a disadvantage, in that when the building, or part of it, is demolished for redevelopment, this releases a large quantity of individual beads which can be carried readily by the wind to pollute the surroundings.
  • the present invention provides a building composition
  • the binder may be thermosetting, or it may be an aqueous film- forming material. Alternatively, the binder may be caused to harden by the addition of a catalyst or by exposure to ultra-violet radiation (for thin films or components).
  • the binder is preferably cellulose- or starch-based, or polyvinyl alcohol based, and curing of the binder may be effected using warm air or steam.
  • Elevated temperatures in the context of the invention, means tem- peratures in excess of normal ambient temperatures, and preferably in the range 50° to 90° C.
  • the binder, when hardened, is not significantly soluble in water at ambient temperatures
  • the filler may be sand, or aggregate, or the like, or hollow beads.
  • the hollow beads may be expanded polystyrene or other plastics, or glass or ceramic bubbles.
  • the beads may have a mean size of up to 10mm, preferably below 5mm, for insulation applications, or very fine, with particle sizes less than 1 mnn, for surface coating compositions.
  • Other possible filler materials included perlite or vermiculite, and comminuted waste glass. Fibres, for example of plastics, minerals or glass, may also be incorporated to improve the strength of the hardened composition
  • the invention also provides building components formed by moulding a composition according to the invention, and allowing or causing the composition to harden.
  • the composition may be cast into blocks, and sheets may be formed if required by slicing the blocks.
  • the composition may be extruded to form continuous lengths of any desired profile, the extruded material being cut to form sections of any desired length. Warm air may be used to hasten the hardening of the extruded material.
  • the composition may be used as a paint, for example as an anti- graffiti paint which can be removed from the surface, along with any graffiti, by the application of hot water.
  • a composition of the invention may be used as a temporary mortar or concrete, or as a rendering or finishing coat applied by trowel or float to a wall or other building surface.
  • a method of cavity wall insulation may comprise injecting into the cavity a composition according to the invention comprising expanded plastics beads.
  • a very light coating of the binder would be sufficient to hold the beads together in the event of demolition of the cavity wall, permitting the material to be recovered and treated with hot water to remove the binder and permit re-use of the beads.
  • the binder could be sprayed into the cavity with the polystyrene or other plastics beads, suitably from a separate nozzle within or alongside the nozzle conventionally used for injection of the beads.
  • composition it would also be possible to use the composition to form an external insulation layer on an existing building which does not have a cavity, either by attaching boards formed from the composition and containing expanded plastics beads or other hollow beads, to the outside surface of the building, or by spraying on the composition in slurry form and allowing it to harden. A protective layer of waterproofing material can then be applied in either case.
  • loft insulation could be achieved by the spraying of an insulating composition according to the invention. After hardening, the composition would be dust-free and stable, and the introduction into the composition of fire- inhibitors and the like would ensure its safety in use.
  • composition including hollow plastics beads may be moulded to form packaging materials for use in protecting products in transit, for example fragile products such as TVs and computer monitors.
  • the packaging can be treated with hot water to wash away the set binder, allowing the beads to be collected in bulk for re-use in further packaging.
  • New binder can be added and the resultant composition moulded to provide custom packaging components.
  • the re-usability of the beads could conveniently be indicated by manufacturing the beads with a suitable dye or pigment added, for example colouring the beads green.
  • composition of the invention may be rendered fire-resistant by incorporating such materials as cement powder.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Electromagnetism (AREA)
  • Acoustics & Sound (AREA)
  • Ceramic Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Polymers & Plastics (AREA)
  • Medicinal Chemistry (AREA)
  • Sustainable Development (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Paints Or Removers (AREA)

Abstract

A building composition comprises a filler, preferably substantially hollow beads, mixed with a hardenable binder which, when hardened, is soluble in water at elevated temperatures. The hardened composition, for example in the form of building or packaging components, can be readily recycled by the use of hot water to remove the binder.

Description

BUILDING COMPOSITION AND RECYCLABLE BUILDING AND PACKAGING COMPONENTS FORMED THEREFROM
Field of the Invention
[0001] This invention relates to a building composition, for example for form- ing structural and decorative components, and in particular to materials which can be readily recycled for re-use when the building is no longer required. The composition can also be used to form packaging. The hardened composition is readily recyclable.
Background to the Invention
[0002] The use of waste and recycled materials as a filler for building materials is well-known. For example, power station ash has been used for the manufacture of building blocks, and recycled glass particles have also been used in building products. Typically, the binder used for these types of product has been cement-based or, more recently, resin-based. While these have proved generally satisfactory for some construction uses, they present a problem when the building is altered or demolished, because they typically require high-powered crushing machines to reduce the blocks and other components to particles for re-use or disposal.
[0003] Cavity wall insulation introduced into existing cavity walls is typically in the form of expanded plastics beads, for example polystyrene beads, which are carried into the cavity from a suitable injection point by a current of air. This enables the cavity to be filled from a relatively small number of injection points, minimising disruption to the building during the operation. While this method does afford a significant improvement in the insulative properties of the walls, it does have a disadvantage, in that when the building, or part of it, is demolished for redevelopment, this releases a large quantity of individual beads which can be carried readily by the wind to pollute the surroundings. While arrangements can be made to extract at least some of the beads before demolition takes place, this is a difficult operation, and is unlikely to remove all the beads, leaving some to escape when demolition takes place. [0004] A common problem in public places is the painting of graffiti on buildings and other structures. This requires considerable work, and therefore cost, to remove. It is known to provide coatings to make it more difficult for the graffiti to adhere to the surfaces, and therefore easier to clean off, but these coatings can adversely affect the appearance of the surfaces, particularly as the coatings age.
[0005] Expanded polystyrene and the like is extensively used in packaging materials, being light in weight and strong enough to provide protection to items during shipping. However, the disposal of packaging materials of this type cre- ates a considerable problem, because of its high volume, relative to its mass, and the difficulty in re-using the material. A large amount of the material therefore ends up in landfill, which is an increasingly costly means of disposal. It is also very slow to degrade, and if broken up can be carried by the wind and left in unsightly deposits.
Summary of the Invention
[0006] The present invention provides a building composition comprising a filler mixed with a hardenable binder which, when hardened, is soluble in water at elevated temperatures.
[0007] The binder may be thermosetting, or it may be an aqueous film- forming material. Alternatively, the binder may be caused to harden by the addition of a catalyst or by exposure to ultra-violet radiation (for thin films or components). The binder is preferably cellulose- or starch-based, or polyvinyl alcohol based, and curing of the binder may be effected using warm air or steam.
[0008] "Elevated temperatures", in the context of the invention, means tem- peratures in excess of normal ambient temperatures, and preferably in the range 50° to 90° C. The binder, when hardened, is not significantly soluble in water at ambient temperatures
[0009] The filler may be sand, or aggregate, or the like, or hollow beads. The hollow beads may be expanded polystyrene or other plastics, or glass or ceramic bubbles. The beads may have a mean size of up to 10mm, preferably below 5mm, for insulation applications, or very fine, with particle sizes less than 1 mnn, for surface coating compositions. Other possible filler materials included perlite or vermiculite, and comminuted waste glass. Fibres, for example of plastics, minerals or glass, may also be incorporated to improve the strength of the hardened composition [0010] The invention also provides building components formed by moulding a composition according to the invention, and allowing or causing the composition to harden. For example, the composition may be cast into blocks, and sheets may be formed if required by slicing the blocks. Alternatively, the composition may be extruded to form continuous lengths of any desired profile, the extruded material being cut to form sections of any desired length. Warm air may be used to hasten the hardening of the extruded material.
[0011] The composition may be used as a paint, for example as an anti- graffiti paint which can be removed from the surface, along with any graffiti, by the application of hot water. Alternatively, a composition of the invention may be used as a temporary mortar or concrete, or as a rendering or finishing coat applied by trowel or float to a wall or other building surface.
[0012] A method of cavity wall insulation may comprise injecting into the cavity a composition according to the invention comprising expanded plastics beads. A very light coating of the binder would be sufficient to hold the beads together in the event of demolition of the cavity wall, permitting the material to be recovered and treated with hot water to remove the binder and permit re-use of the beads. For example, the binder could be sprayed into the cavity with the polystyrene or other plastics beads, suitably from a separate nozzle within or alongside the nozzle conventionally used for injection of the beads.
[0013] It would also be possible to use the composition to form an external insulation layer on an existing building which does not have a cavity, either by attaching boards formed from the composition and containing expanded plastics beads or other hollow beads, to the outside surface of the building, or by spraying on the composition in slurry form and allowing it to harden. A protective layer of waterproofing material can then be applied in either case. [0014] Similarly, loft insulation could be achieved by the spraying of an insulating composition according to the invention. After hardening, the composition would be dust-free and stable, and the introduction into the composition of fire- inhibitors and the like would ensure its safety in use.
[0015] The use of cellulose- or starch-based or polyvinyl alcohol-based ad- hesives or the like means that the treatment of the hardened material with hot water to recover the beads does not produce any environmentally harmful residues; the wash water can be disposed of in the sewerage system without special treatment. [0016] The composition including hollow plastics beads may be moulded to form packaging materials for use in protecting products in transit, for example fragile products such as TVs and computer monitors. When the products are unpacked at their destination, the packaging can be treated with hot water to wash away the set binder, allowing the beads to be collected in bulk for re-use in further packaging. New binder can be added and the resultant composition moulded to provide custom packaging components. The re-usability of the beads could conveniently be indicated by manufacturing the beads with a suitable dye or pigment added, for example colouring the beads green.
[0017] The composition of the invention may be rendered fire-resistant by incorporating such materials as cement powder.

Claims

1 . A building composition comprising a filler mixed with a hardenable binder which, when hardened, is soluble in water at elevated temperatures.
2. A building composition according to Claim 1 , wherein the binder is cellulose- or starch-based, or polyvinyl alcohol based.
3. A building composition according to Claim 1 or 2, wherein the binder is thermosetting, or an aqueous film-forming material.
4. A building composition according to Claim 1 or 2, wherein the binder is hardenable by the action of a catalyst or by exposure to ultra-violet ra- diation.
5. A building composition according to an preceding claim, wherein the filler comprises substantially hollow beads.
6. A building composition according to Claim 5, wherein the hollow beads are expanded polystyrene or other plastics, or glass or ceramic bubbles.
7. A building composition according to Claim 5 or 6, wherein the beads have a mean size of less than 1 mm.
8. A building composition according to Claim 5 or 6, wherein the beads have a mean size of up to 5mm.
9. A method of making a building component, comprising moulding a composition according to any preceding claim, and allowing or causing the composition to harden.
10. A method of cavity wall insulation, comprising injecting into the cavity of an existing wall a composition according to Claim 1 comprising expanded plastics beads.
PCT/GB2010/051628 2009-09-30 2010-09-29 Building composition and recyclable building and packaging components formed therefrom WO2011039538A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0917144.8 2009-09-30
GB0917144A GB2474023A (en) 2009-09-30 2009-09-30 Recyclable composition for building materials

Publications (1)

Publication Number Publication Date
WO2011039538A1 true WO2011039538A1 (en) 2011-04-07

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PCT/GB2010/051628 WO2011039538A1 (en) 2009-09-30 2010-09-29 Building composition and recyclable building and packaging components formed therefrom

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WO (1) WO2011039538A1 (en)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0053411A1 (en) * 1980-12-02 1982-06-09 Shell Internationale Researchmaatschappij B.V. Filler gun suitable for cavity injection
CS224523B1 (en) * 1981-12-23 1984-01-16 Jan Ing Sequens Thermal insulating material for filling cavities in a panel or other elements of facede
DE9200066U1 (en) * 1992-01-04 1992-02-27 Schrieder, Werner, 63814 Mainaschaff Insulating material
DE202008003235U1 (en) * 2008-03-07 2008-06-05 Btf Produktentwicklungs- Und Vertriebs-Gmbh Aqueous putty, especially for internal insulation
US20090032252A1 (en) * 2007-07-30 2009-02-05 Boney Curtis L Degradable cement compositions containing degrading materials and methods of cementing in wellbores

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4990563A (en) * 1989-09-25 1991-02-05 Aqualon Company Water soluble silated polyvinyl alcohol
EP0960922A1 (en) * 1998-05-26 1999-12-01 Aventis Research & Technologies GmbH & Co KG Method for preparing a protein coating and articles thereof
CN101200366A (en) * 2007-12-29 2008-06-18 曹国宝 Polyphenyl granule heat-preservation thermal insulating slurry containing rear-earth catalyst

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0053411A1 (en) * 1980-12-02 1982-06-09 Shell Internationale Researchmaatschappij B.V. Filler gun suitable for cavity injection
CS224523B1 (en) * 1981-12-23 1984-01-16 Jan Ing Sequens Thermal insulating material for filling cavities in a panel or other elements of facede
DE9200066U1 (en) * 1992-01-04 1992-02-27 Schrieder, Werner, 63814 Mainaschaff Insulating material
US20090032252A1 (en) * 2007-07-30 2009-02-05 Boney Curtis L Degradable cement compositions containing degrading materials and methods of cementing in wellbores
DE202008003235U1 (en) * 2008-03-07 2008-06-05 Btf Produktentwicklungs- Und Vertriebs-Gmbh Aqueous putty, especially for internal insulation

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
CHEMICAL ABSTRACTS, vol. 104, no. 14, 7 April 1986, Columbus, Ohio, US; abstract no. 115018v, SEQUENS, J.: "Heat-insulating filling material for cavities in buidling structures" page 328; XP000061308 *

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Publication number Publication date
GB0917144D0 (en) 2009-11-11
GB2474023A (en) 2011-04-06

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