WO2017025786A1 - Procédé de production de matériaux composites durables conçus pour la production d'éléments destinés à une utilisation structurale ou non structurale, et matériau ainsi obtenu - Google Patents

Procédé de production de matériaux composites durables conçus pour la production d'éléments destinés à une utilisation structurale ou non structurale, et matériau ainsi obtenu Download PDF

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Publication number
WO2017025786A1
WO2017025786A1 PCT/IB2016/001065 IB2016001065W WO2017025786A1 WO 2017025786 A1 WO2017025786 A1 WO 2017025786A1 IB 2016001065 W IB2016001065 W IB 2016001065W WO 2017025786 A1 WO2017025786 A1 WO 2017025786A1
Authority
WO
WIPO (PCT)
Prior art keywords
fibrous
bioplastic
mould
casing
structural
Prior art date
Application number
PCT/IB2016/001065
Other languages
English (en)
Inventor
Matteo BARBARI
Leonardo CONTI
Bernardo MONTI
Massimo Monti
Giuseppe Rossi
Federico Rotini
Marco TOGNI
Original Assignee
Universita' Degli Studi Di Firenze
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
Priority claimed from ITUB2015A003019A external-priority patent/ITUB20153019A1/it
Priority claimed from ITUB2015A003007A external-priority patent/ITUB20153007A1/it
Application filed by Universita' Degli Studi Di Firenze filed Critical Universita' Degli Studi Di Firenze
Priority to CN201680045803.6A priority Critical patent/CN108026726A/zh
Priority to EP16763563.0A priority patent/EP3332072B1/fr
Publication of WO2017025786A1 publication Critical patent/WO2017025786A1/fr

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C1/00—Building elements of block or other shape for the construction of parts of buildings
    • E04C1/40—Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
    • 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

Definitions

  • the invention relates to a new method for the production of pre-compressed elements made of composite material, such as blocks, panels, also for packaging, prefabricated walls, beams, and slabs for structural or non-structural use in the building sector, and the material thus obtained.
  • the method envisages production of pre-compressed elements, such as blocks, panels, prefabricated walls, beams, and slabs, with a composite material comprising an amount of compostable dry fibrous organic material in the compressive state, contained within closed cells, the foregoing all contained within a casing.
  • the cells and the casing are in the tensile state and made of compostable heat-meltable organic polymers, said fibrous organic material and said cells and casing being configured for maintaining a permanent state of co-action with the fibrous organic material permanently compressed and the casing made of bioplastic material permanently tensioned.
  • the material obtained is a composite material prevalently constituted by compostable dry fibrous organic materials, amongst which there may be listed, even though the list is not exhaustive, straw, stalks, reeds, leaves, twigs, grass, materials deriving from the processing of wood, feathers, animal bristles, or mixtures thereof, and for the remaining part by materials that possess a degree of environmental sustainability similar to that of the aforesaid fibrous organic materials, i.e. , compostable organic biopolymers deriving from widely cultivated vegetal species. All the component materials are compostable in accordance with the UNI EN1 3432 standard.
  • the method according to the invention consequently envisages production of a composite material, constituted by a mixture of fibrous organic materials and solid-state bioplastic materials, and then in succession steps of compression and heating, for example with the use of generators of high-frequency electromagnetic radiation (microwaves).
  • a composite material constituted by a mixture of fibrous organic materials and solid-state bioplastic materials
  • steps of compression and heating for example with the use of generators of high-frequency electromagnetic radiation (microwaves).
  • the elements thus obtained present both structural load-bearing characteristics and characteristics of thermal insulation, and can be used in the building sector, as blocks, panels, prefabricated walls, beams, and slabs, to replace elements made of other materials, currently widespread in the building sector, such as thermally insulating brick blocks, expanded-clay blocks, autoclaved-aerated-concrete blocks, thermally insulated panels, prefabricated walls, prefabricated beams, prefabricated pillars, and prefabricated slabs.
  • Prior art
  • CN 1 0341 9393 are a mould and the pressing device for a process for forming a straw building block.
  • CN102328336 is a method for producing brick tiles and prefabricated components with stalks of various species, weeds, and an adhesive with a base of polyurethane foam, which envisages cutting the weeds and stalks to a variable length, drying the material using microwaves, mixing with glue, moulding, adding polyurethane-foam adhesive, followed by a step of hot pressing.
  • a heat-shrinking system that comprises within it a layer of straw (or alternatively various polymers, such as expanded polyurethane or polystyrene, or waste products) for the production of building blocks.
  • a self-propelled machine capable of stacking and compressing the straw in all directions in space, heating it with a microwave heater, compressing it, and then cooling it to obtain a block.
  • a first drawback lies in the fact that none of the systems of a known type envisages production of elements constituted exclusively by compostable materials.
  • a second drawback lies in the fact that the systems of a known type envisage a step of compression of fibrous materials of natural origin for the formation of elements, generally after prior wetting thereof, but do not envisage the capacity of the elements to maintain the internal state of stress, and consequently are not in a state of pre-compression in their configuration of use.
  • a further drawback lies in the fact that none of the systems of a known type envisages the production of elements constituted exclusively by compostable materials.
  • the materials of a known type are defined as "pre-compressed" simply in the sense that during packaging the product is compressed, but not that it is able to maintain its internal stresses.
  • the fibrous organic material in the cases where, during packaging, the fibrous organic material is wet with any liquid, it loses almost completely its own mechanical characteristics of elastic return in so far as, instead of tending to re-assume its own initial shape, it adapts "plastically" to the new shape that is imposed by the compression process.
  • a first purpose of the invention is to propose a method for producing pre-compressed elements made of composite material comprising fibrous material, for example straw, and a binding material, which, during preparation, are subjected one to compression and the other to tension, in such a way that, once the element is obtained and has acquired its final shape, it substantially preserves, for each of its own component materials, the compressive and tensile internal stresses.
  • a purpose of the invention is to produce elements for building purposes constituted exclusively by compostable materials.
  • a first advantage lies in the fact that the method enables production of prefabricated elements subject to states of internal co-action, in particular pre-compression, that are designed to improve the behaviour thereof during use.
  • the elements produced with the present system are "pre-tested" for compression in so far as, during their production, they are subjected to stresses much higher than the ones that they will be required to withstand during use.
  • a further advantage of the method lies in the fact that pre-compression reduces to a significant extent the deformations of the block during use.
  • a further advantage of the method l ies in the fact that it enables a composite material to be obtained, and hence elements produced therewith, which have a volumic mass having a value that may vary according to the uses to which they are put, i.e., whereby to a greater force of compression exerted during manufacture there corresponds a higher value of the final volumic mass, and hence a higher mechanical load-bearing capacity and a lower thermal insulation.
  • a further advantage lies in the fact that the elements obtained possess high characteristics of both thermal and acoustic insulation, due both to the intrinsic properties of the component materials (fibrous organic material and binding material, i.e. , compostable biopolymers) and to the fact that entrapped within it are an extremely high n umber of air cells not communicating with one another or with the outside world.
  • a further advantage lies in the fact that the element obtained is not only biodegradable, but totally compostable in so far as it is made up only of materials that are compostable according to the UNI EN 13432 standard and hence possess an extremely high degree of environmental sustainability.
  • FIG. 1 shows an example, in cross-sectional view in any direction, of an element made of a material according to the method of the invention, highlighted in which is the arrangement within the element of the materials making up the composite material;
  • Figure 2 shows examples, in axonometric view, of elements obtained with the material of the invention according to Figure 1 in modular conformation;
  • Figure 3 shows examples, in a second axonometric view, of elements according to Figure 1 in modular conformation
  • Figures 4a, 4b show examples, in two orthogonal side views , of blocks obtained with the material of the invention according to Figure 1 in modular conformation;
  • Figures 5-5a show by way of example, in perspective view and cross-sectional view, respectively, an arrangement of fibrous material and bioplastic material for the production of a block obtained with the material of the invention.
  • Figure 6 shows a cross-sectional view of a compression machine for actuating the mould.
  • Described with reference to the attached drawings are a preferred non-limiting embodiment (referring to a masonry block) of a method according to the invention for the production of pre-compressed elements made of composite materials for structural or non -structural use in the building sector.
  • the method envisages preparation of a mould 8 having a shape and dimensions corresponding to the desired final shape and dimensions of the block.
  • the mould 8 is made of a material permeable to high-frequency electromagnetic radiation (microwaves).
  • the mould may be made of aluminium, fibre-glass, wood materials, plastic materials.
  • the mould is formed by side walls 12, a bottom 1 3, and a piston/lid 9 that can slide in the mould for compressing the materials set therein.
  • the mould is of a type that can be taken apart in order to facilitate extraction of the finished block.
  • the method envisages formation of bundles or cylinders 4 formed by the dry fibrous organic material 7, wrapped in a sheet of bioplastic material, and laying on the bottom, on the side walls of the mould, and on top of the cylinders of sheets of bioplastic material so that they will complete the outer coating or casing 2 of the block.
  • bioplastic material an organic polymer of natural origin, such as compostable bioplastic of the type used for the production of compostable bags known by the brand name Mater-bi®, manufactured by the company Novamont S. p.A starting from maize seed.
  • the dry fibrous organic material may be constituted, by way of example by straw, stalks, reeds, leaves, twigs, grass, materials deriving from the processing of wood, feathers, animal bristles, or mixtures thereof, having a length indicatively of not less than 50 mm.
  • dry fibrous organic material is meant a material with a very low water content, for example less than 14%, used dry in so far as it is not moistened at any point during the manufacturing process so that it will preserve its own original physical/mechanical characteristics.
  • the cylinders 4 have a length approximately equal to that of the sid e walls 12 of the mould and have a mean diameter that can be chosen according to the physical/mechanical characteristics that it is desired to obtain for the final block made of composite material.
  • the cylinders 4 are in a number sufficient to fill the mould completely and are arranged vertically, i.e. , according to the direction of sliding of the piston 9, so that the fibres of the fibrous organic material will be perpendicular to the piston/lid.
  • the fibres of the fibrous organic material completely fill the mould and are perpendicular to the piston/lid and, once compressed, assume an arrangement in all directions, and not only horizontal, so as to bestow upon the finished block 1 an adequate shear strength.
  • a pressure can be exerted having a value determined according to the desired final density, i.e. , a higher value for higher densities, and a lower value when a lower density is desired.
  • blocks having a volumic mass of approximately 400 kg/m 3 can be used for erecting load-bearing walls of residential buildings, for example buildings with floor slabs spanning approximately 5 m, up to ten storeys in height, whereas blocks having a volumic mass of approximately 100 kg/m 3 can be used for erecting curtain walls of buildings having a frame structure.
  • these materials may be: netting, or wires, or fabrics made of metal; netting, or wires, or fabrics made of fibre-glass; netting, or wires, or fabrics made of plastic; netting, or wires, or fabrics of an organic nature; granules, or sand, or powders of a non-organic nature; granules, or sand, or powders of an organic nature.
  • the mould can be installed in a pressing mach ine 14 equipped with a stem 10 for operating the piston/lid 9 so that the piston/lid will compress the materials inside, i.e., the cylinders 4 and the sheets of bioplastic material of the casing 2.
  • the value of the pressure to be exerted varies according to the desired final dimensions and density of the block, and may be between 1 .0 N/mm 2 and 13 N/mm 2 , or higher.
  • a pressure of approximately 4 N/mm 2 is required.
  • the method envisages a step of heating up to approximately 80°C, preferably implemented by operating generators 1 1 of high-frequency electromagnetic radiation (microwaves), for the time necessary (for example, approximately 300-600 s) to obtain complete melting of the bioplastic material, and hence gluing thereof to the fibrous organic material.
  • the generators 1 1 are advantageously arranged so as to obtain a uniform distribution of the electromagnetic waves in the mass of the materials contained in the mould.
  • the heating step occurs in such a way that the temperature reached is sufficient to lead to melting of the bioplastic material but not alter the physical/mechanical characteristics of the fibrous organic material.
  • a step of cooling of the materials is carried out, of a forced or spontaneous type, up to solidification of the bioplastic material and to subsequent extraction of the finished block.
  • a finished block 1 comprising an amount of dry fibrous organic material 7 in the compressive state, contained within a casing 2 in the tensile state and made of a heat-meltable bioplastic compostable material.
  • the fibrous organic material is, at the end of the process, constituted by stalks of fibrous material without a single preferential orientation but arranged in all directions.
  • the absence of a preferential direction bestows upon the block shear strength in all directions.
  • the block 1 comprises a extensive honeycomb structure 3 within the block constituted by a tri-directional lattice of heat-meltable bioplastic compostable material, formed by a set of closed cells connected both together and to the outer casing, in which the bioplastic material constituting the outer casing and the walls of the cells adheres to the straw adjacent to the bioplastic material.
  • Figure 1 shows, in particular, the arrangement within the block 1 of the fibrous material 7 and of the closed cells of bioplastic material 3, according to a cross-sectional view of the block taken in any direction, since the pattern of distribution of the closed cells of bioplastic material and of the straw is the same in all directions.
  • a material according to the invention consequently comprises an amount of dry fibrous organic material 7 in the compressive state, contained within a casing 2 in the tensile state, which is made of a heat-meltable bioplastic compostable material.
  • the fibrous organic material and the casing are configured for maintaining a permanent state of co-action, with the fibrous organic material permanently compressed and the casing made of bioplastic material permanently tensioned.
  • the block behaves like a brick tile pre-tested for compressive stresses lower than or equal to the pre-compression value.
  • the absence of a preferential direction bestows upon the block shear strength in all directions.
  • the material of the invention can advantageously be used, for example, for making walls. It is emphasised that this is a possible application of the material. Since the configuration of the element can change if the material is used for making beams or slabs, in this case reinforcement steel will be present.
  • the recesses and the protrusions 5, 6 are obtained on the horizontal faces of the block, but it is understood that, according to the use, the" recesses and the protrusions may be positioned indifferently upwards and/or downwards, and/or laterally on the side faces].
  • a wall according to the invention is made up of a plurality of blocks of the type described above, joined together by means of compostable adhesives, for example glue of animal origin, produced with skins and bones deriving, as waste products, from the processing of hides, or else glue of vegetable origin produced with starches of cereal origin.
  • compostable adhesives for example glue of animal origin, produced with skins and bones deriving, as waste products, from the processing of hides, or else glue of vegetable origin produced with starches of cereal origin.
  • the outer surfaces of the blocks are provided with materials stably adherent to the casing 2, i.e., materials that can bind with the bioplastic that constitutes the casing.
  • the above materials may be: netting, or wires, or fabrics made of metal; netting, or wires, or fabrics made of fibre-glass; netting, or wires, or fabrics made of plastic; netting, or wires, or fabrics of an organic nature; granules, or sand, or powders of a non-organic nature; granules, or sand, or powders of an organic nature.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Processing Of Solid Wastes (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

Cette invention concerne un procédé pour la production d'éléments pré-comprimés faits de matériaux composites, tels que des blocs, des panneaux, des murs préfabriqués, des poutres et des dalles pour une utilisation structurale ou non structurale dans le secteur du bâtiment, comprenant les étapes suivantes : la fourniture d'une certaine quantité d'un matériau organique sec fibreux (7) ; la fourniture d'une première enveloppe externe constituée d'un matériau bio-plastique fusible à la chaleur (2) destinée à contenir le matériau fibreux pour la formation d'un matériau composite ; la fourniture d'une pluralité d'enveloppes internes contenant des parties dudit matériau fibreux ; la compression du matériau composite comprenant le matériau fibreux (7) et les enveloppes externes et internes en plastique ; le chauffage du matériau composite ; et le refroidissement du matériau composite.
PCT/IB2016/001065 2015-08-07 2016-07-28 Procédé de production de matériaux composites durables conçus pour la production d'éléments destinés à une utilisation structurale ou non structurale, et matériau ainsi obtenu WO2017025786A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
CN201680045803.6A CN108026726A (zh) 2015-08-07 2016-07-28 一种制备用于生产结构性或非结构性用途预压件的可持续复合材料的方法及该复合材料
EP16763563.0A EP3332072B1 (fr) 2015-08-07 2016-07-28 Procédé de production de matériaux composites durables conçus pour la production d'éléments destinés à une utilisation structurale ou non structurale, et matériau ainsi obtenu

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
IT102015000043284 2015-08-07
IT102015000043241 2015-08-07
ITUB2015A003019A ITUB20153019A1 (it) 2015-08-07 2015-08-07 Metodo di realizzazione di materiali compositi sostenibili atti alla produzione di elementi per impiego strutturale e non strutturale in edilizia.
ITUB2015A003007A ITUB20153007A1 (it) 2015-08-07 2015-08-07 Materiale composito sostenibile atto alla produzione di elementi per impiego strutturale e non strutturale in edilizia.

Publications (1)

Publication Number Publication Date
WO2017025786A1 true WO2017025786A1 (fr) 2017-02-16

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PCT/IB2016/001065 WO2017025786A1 (fr) 2015-08-07 2016-07-28 Procédé de production de matériaux composites durables conçus pour la production d'éléments destinés à une utilisation structurale ou non structurale, et matériau ainsi obtenu

Country Status (3)

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EP (1) EP3332072B1 (fr)
CN (1) CN108026726A (fr)
WO (1) WO2017025786A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20180186957A1 (en) * 2017-01-05 2018-07-05 City University Of Hong Kong Composite material composition and a method of forming a composite material composition

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11661740B2 (en) 2021-10-07 2023-05-30 ORB Technologies, LLC System, apparatus, and method for providing a plant-based structural assembly

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CA283718A (fr) * 1928-10-02 Tchayeff Serge Planche comprimee et armee
US2369006A (en) * 1941-10-27 1945-02-06 Banks John Leon Menzies Stone Structural material
FR1525387A (fr) * 1967-04-07 1968-05-17 Nouveau parpaing insonorisé et son procédé de fabrication
US3664076A (en) * 1970-03-02 1972-05-23 Wagner John E Random honeycomb structure
US4774121A (en) * 1986-06-16 1988-09-27 Vollenweider Ii Edward E Core for composite structures
CA2125706A1 (fr) * 1994-06-13 1995-12-14 Yvon Saucier Paillobloc
DE19610247A1 (de) * 1995-08-08 1997-02-13 Peter Dr Schopf Einsatz von nachwachsenden Rohstoffen für Industrieprodukte, z. B. für Bauzwecke, und aus derartigen Rohstoffen hergestellte Produkte, z. B. Bauelemente
CA2229589A1 (fr) * 1998-04-22 1999-10-22 Robert Platts Methode a sec pour recycler, dans des blocs de maconnerie, des fibres organiques et d'autres materiaux polymerises
US20030208982A1 (en) * 2002-05-10 2003-11-13 Korman Benjamin Z. Culm blocks
US20060062959A1 (en) * 2002-04-30 2006-03-23 Gerardo Elpidio Mata S Light prefabricated module made from natural reed and used as a construction element
US20110159295A1 (en) * 2011-03-07 2011-06-30 Angelo Marra Biomass article and method of manufacturing
FR2969188A1 (fr) * 2010-12-21 2012-06-22 Christian Martin Element constructif de construction pour batiment

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CN1080012A (zh) * 1992-06-10 1993-12-29 科林·马克·理查德·埃利斯 结构件及其制造方法
CN102276870B (zh) * 2011-04-28 2013-04-24 中国科学院宁波材料技术与工程研究所 生物降解聚合物硬质复合结构泡沫板材的制备方法
CN102352667B (zh) * 2011-11-07 2012-11-28 张智慧 一种以芦苇为原材料的建筑外墙保温板及其生产方法
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Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA283718A (fr) * 1928-10-02 Tchayeff Serge Planche comprimee et armee
US2369006A (en) * 1941-10-27 1945-02-06 Banks John Leon Menzies Stone Structural material
FR1525387A (fr) * 1967-04-07 1968-05-17 Nouveau parpaing insonorisé et son procédé de fabrication
US3664076A (en) * 1970-03-02 1972-05-23 Wagner John E Random honeycomb structure
US4774121A (en) * 1986-06-16 1988-09-27 Vollenweider Ii Edward E Core for composite structures
CA2125706A1 (fr) * 1994-06-13 1995-12-14 Yvon Saucier Paillobloc
DE19610247A1 (de) * 1995-08-08 1997-02-13 Peter Dr Schopf Einsatz von nachwachsenden Rohstoffen für Industrieprodukte, z. B. für Bauzwecke, und aus derartigen Rohstoffen hergestellte Produkte, z. B. Bauelemente
CA2229589A1 (fr) * 1998-04-22 1999-10-22 Robert Platts Methode a sec pour recycler, dans des blocs de maconnerie, des fibres organiques et d'autres materiaux polymerises
US20060062959A1 (en) * 2002-04-30 2006-03-23 Gerardo Elpidio Mata S Light prefabricated module made from natural reed and used as a construction element
US20030208982A1 (en) * 2002-05-10 2003-11-13 Korman Benjamin Z. Culm blocks
FR2969188A1 (fr) * 2010-12-21 2012-06-22 Christian Martin Element constructif de construction pour batiment
US20110159295A1 (en) * 2011-03-07 2011-06-30 Angelo Marra Biomass article and method of manufacturing

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20180186957A1 (en) * 2017-01-05 2018-07-05 City University Of Hong Kong Composite material composition and a method of forming a composite material composition
US10737458B2 (en) * 2017-01-05 2020-08-11 City University Of Hong Kong Composite material composition and a method of forming a composite material composition

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Publication number Publication date
EP3332072B1 (fr) 2019-05-08
CN108026726A (zh) 2018-05-11
EP3332072A1 (fr) 2018-06-13

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