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WO2018195599A1 - Composite panel - Google Patents

Composite panel Download PDF

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Publication number
WO2018195599A1
WO2018195599A1 PCT/AU2018/050381 AU2018050381W WO2018195599A1 WO 2018195599 A1 WO2018195599 A1 WO 2018195599A1 AU 2018050381 W AU2018050381 W AU 2018050381W WO 2018195599 A1 WO2018195599 A1 WO 2018195599A1
Authority
WO
WIPO (PCT)
Prior art keywords
composite panel
core
accordance
moulded core
reinforcing mesh
Prior art date
Application number
PCT/AU2018/050381
Other languages
French (fr)
Inventor
Stephin John MARSKELL
Original Assignee
One Stop Marketing Solutions Pty Ltd
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 AU2017901537A external-priority patent/AU2017901537A0/en
Application filed by One Stop Marketing Solutions Pty Ltd filed Critical One Stop Marketing Solutions Pty Ltd
Publication of WO2018195599A1 publication Critical patent/WO2018195599A1/en
Priority to AU2019101232A priority Critical patent/AU2019101232A4/en

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/102—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of fibrous or chipped materials, e.g. bonded with synthetic resins
    • 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
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/043—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of metal
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/14—Layered products comprising a layer of metal next to a 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/16—Layered products comprising a layer of metal next to a particulate 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • 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
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/042—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of wood
    • 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
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/10—Next to a 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
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/12—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board next to a particulate 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
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/14—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood board or veneer
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
    • 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
    • B32B5/022—Non-woven fabric
    • 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
    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
    • 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
    • B32B5/16—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 features of a layer formed of particles, e.g. chips, powder or granules
    • 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
    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • 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
    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/30—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being formed of particles, e.g. chips, granules, powder
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • B32B7/022—Mechanical properties
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/002—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising natural stone or artificial stone
    • 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
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular 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
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/047—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material made of fibres or filaments
    • 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
    • C04B26/285—Cellulose or derivatives thereof
    • 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
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/30—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing magnesium cements or similar cements
    • C04B28/32—Magnesium oxychloride cements, e.g. Sorel cement
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/14—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/05—5 or more layers
    • 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/04—Coating on the layer surface on a particulate 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
    • 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
    • B32B2260/025—Particulate layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
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    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/102—Oxide or hydroxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
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    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
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    • B32B2607/00—Walls, panels
    • C—CHEMISTRY; METALLURGY
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    • 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
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
    • E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
    • E04F2290/045—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against fire

Definitions

  • the present invention relates to composite panels such as composite building panels and a method of building the composite panels.
  • the composite panels may include but not be limited to facade panels, floor panels and wall panels used in the building industry.
  • composite panels are used for external walls, facades and even floor installations.
  • composite panels can exhibit many advantageous features such as being weather proof, noise absorbing, fireproof, light and easy to cut, impact resistant and easy to maintain.
  • construction panels such as fagade panels and floor panels must comply with strict building code regulations for fire resistance. Accordingly, there is a need for providing composite building panels with improved fire-resistance properties.
  • the invention comprises a composite panel comprising:
  • the invention comprises a composite panel comprising: a moulded core having at least 30wt% magnesium oxide; and two spaced apart outer sheets for positioning the core therebetween;
  • each of said outer sheet is adhesively bonded to the moulded core.
  • the moulded core comprises at least one reinforcing mesh of a first type positioned in an interior portion of the moulded core.
  • the moulded core further comprises at least one additional reinforcing mesh of a second type positioned in a spaced relationship relative to the at least one reinforcing mesh of the first type.
  • the at least one additional reinforcing mesh of the second type is positioned adjacent the outer surface of the moulded core.
  • tensile strength of the reinforcing mesh of the first type is different from tensile strength of the reinforcing mesh of the second type.
  • tensile strength of the reinforcing mesh of the second type is lower relative to tensile strength of the reinforcing mesh of the first type.
  • At least one of the reinforcing mesh is oriented in the moulded core in a substantially parallel orientation relative to the outer sheets.
  • each of the outer sheets comprises a sheet thickness, the sheet thickness being less than or equal to a thickness of the core.
  • a thickness of at least one of the outer sheets is greater than a thickness of the other of the outer sheets. In some embodiments, thickness of at least one outer sheet may be greater than thickness of the core. In an embodiment, the core comprises less than 60wt% magnesium oxide.
  • the moulded core further comprises a binding agent and/or a filling agent.
  • the moulded core further comprises a dispersing agent to disperse the contents of the core.
  • the outer sheet comprises a metallic sheet.
  • the metallic sheet comprises aluminum or aluminum alloys.
  • the outer sheet comprises veneer.
  • the outer sheet comprises an engineered stone slab or natural stone slab.
  • the outer sheet comprises laminate material.
  • the moulded core further comprises a fabric layer positioned along at or adjacent an outer portion of the core
  • the invention comprises a method of manufacturing a composite panel, the method comprising:
  • a respective outer sheet is adhesively bonded to two opposite outer surfaces such that the core is positioned between two outer sheets.
  • Figure 1 is a sectional end view of a composite panel 100 in accordance with a first embodiment.
  • Figure 2 is a schematic sectional view of the composite panel 100.
  • Figure 3 is top orthogonal view of a composite panel 200 in accordance with a second embodiment.
  • Figure 4 is an end view of the composite panel 200.
  • Figure 5 is a top view of the composite panel 200.
  • Figure 6 is a top orthogonal view of a composite panel 300 in accordance with a third embodiment.
  • Figure 7 is an end view of the composite panel 300.
  • Figure 8 illustrates two composite panels 300A and 300B in a disconnected configuration.
  • Figure 9 illustrates two composite panels 300A and 300B in an interconnected configuration.
  • Figure 10 is an illustration of two composite panels 400A and 400 in accordance with a fourth embodiment of the present invention.
  • the present invention relates to a construction board in the form a composite panel 100 that offers a combination of a high degree of fire resistance, a high density, high flexural strength, and effective moisture and water resistance.
  • the composite panel also comprises two spaced apart outer sheets 60 and 70 for positioning the moulded core 30 there-between.
  • Each of the outer sheets 610 and 70 is adhesively bonded to opposite sides of the moulded core 30.
  • the advantageous properties of the composite panel 100 are attained by a combination of the moulded core 30 sandwiched in between the outer sheets 60 and 70.
  • the moulded core 30 is formulated to include about 30% to about 60% by weight of the magnesium oxide with at least 10% by weight of magnesium chloride.
  • the composite panel may also include magnesium sulphate.
  • the core 30 also incorporates one or more hydrophobic agents. Such hydrophobic agents may be added in order to increase the overall water-resistance of the panel 100. Any suitable hydrophobic agent may also be used during panel manufacture.
  • the core material further comprises additives such as a binding agent like cellulose (at least % to about 20% by weight), perlite (preferably 6- 12% by weight) and dispersants. The combination of these core mixtures ingredients yield a panel core 30 that contributes to the enhanced flexural strength of the resulting panel 100.
  • the core material 30 may incorporate one or more fillers that serve to lower the weight of the panel.
  • the moulded core 30 comprises reinforcing mesh 15 and 25 are also provided within the moulded core 30. Specifically, additional mesh 15 is positioned adjacent to the first outer surface (or top surface) 10. Similarly, additional mesh 25 is positioned adjacent to the second outer surface (bottom surface) 20.
  • the mesh 15, 25 and 50 are arranged in a mutually parallel configuration and are substantially co-parallel with the plane of the first and second opposite outer surfaces 10 and 20.
  • the present embodiment provides a configuration whereby, the combination of the inwardly located mesh 50 and the outwardly located mesh 15 and 25 improves the overall structural performance of the panel 100 during use. Furthermore still, a pair of non- woven fabric sheets 12 and 22 is also included in between the additional reinforcing mesh (15 and 25) and the respective outer surfaces (10 and 20). At least a part of the outer surface of the moulded core 30 is positioned contiguously with the outer sheets 60 and 70 so that the fabric sheets 12 and 22 lie in close proximity to the outer sheets 60 and 70. The inventors have surprisingly found that positioning the fabric sheets 12 and 22 in the aforementioned configuration assists with improving the in-use characteristics of the composite panel 100.
  • the outer sheets 60 and 70 may comprise a metallic material such aluminium or aluminium containing alloy.
  • the outer sheets 60 and 70 are adhesively bonded to opposite outer surfaces of the moulded core 30 to form the composite panel 100.
  • the inventors have found that positioning each of the outwardly located reinforcing mesh 15 and 25 in the moulded core 30 in close proximity to the outer sheets 60 and 70 provides an unexpected and significant improvement in structural flexural strength of the composite panel 100.
  • the composite panel comprises a core 230 which possesses substantially similar characteristics as the core 230 which has been described in previous sections.
  • the core 230 is laminated on opposite surfaces with flat sheets of aluminium (260 and 270) that have a thickness in the range of 0.5 to 0.7 gauge.
  • the flat sheets of aluminium (260 and 270) are adhesively bonded to the opposite surfaces of the core 230.
  • the composite panels 200 are particularly useful for use as cladding panels or facade panels that can be readily fastened to an outwardly facing wall of a building.
  • the panels 200 are light-weight and fire resistant and provide a much improved alternative to existing cladding panels that are currently available.
  • Each of the outer sheets 260 and 270 have a similar thickness that is substantially less than the thickness of the core 230.
  • the composite panel comprises a core 330 which possesses substantially similar characteristics as the core 330 which has been described in previous sections.
  • the core 330 is laminated on opposite surfaces with flat sheets of veneer (360 and 370) that have a thickness in the range of 0.5 to 0.7 gauge.
  • the flat sheets of veneer (360 and 370) are adhesively bonded to the opposite surfaces of the core 330.
  • the composite panels 300 are particularly useful for use as flooring panels. Referring to Figures 8 and 9 in particular, panels 300A and 300B may be provided with an inter-locking arrangement provided along an edge portion of each panel 300A and 300B for inter-locking the panels 300A and 300B during use.
  • Each of the outer sheets 360 and 370 have a similar thickness that is substantially less than the thickness of the core 330.
  • the composite panel also comprises a core 430 which possesses substantially similar characteristics as the core 430 which has been described in previous sections.
  • the core 430 is laminated on opposite surfaces with flat sheets of two different materials.
  • a first outer sheet of veneer 470 is positioned on a first outer face of the core 430 and a second sheet 460 (having a greater thickness relative to the first sheet 470).
  • the second sheet 460 may comprise of any material other than veneer.
  • the passages below describe one of many possible methods which may be utilised for moulding the core 30 of the composite panel 100 for the preferred embodiment.
  • the method includes a plurality of steps, which will be described below in detail. The order of least some of the steps may be varied from that shown and at least some of the actions may be performed sequentially or concurrently.
  • the constituents forming the moulded core 30 are in accordance with the amounts as described previously.
  • a dry mixing step is carried out in which at least the magnesium oxide, the magnesium chloride and the perlite is mixed to obtain a homogenised dry mixture.
  • the magnesium oxide, magnesium chloride and perlite ingredients are initially mixed to form a dry powdery mixture.
  • 30% to about 60% by weight of the magnesium oxide, about at least 10% by weight of the magnesium chloride and about 6-12% by weight of perlite is mixed.
  • the binding agent provided in the form of alpha cellulose functions to bind the composition together and may also comprise further additives.
  • the method includes mixing the dry powder with water in a mixing chamber in a slurry preparation step.
  • Tap water may be used.
  • the water solution may be stirred periodically over a period of time, by stirring means.
  • the mixing results in the formation of a slurry 630 with a past like consistency or viscosity.
  • the next step comprises lining the mould with a non-woven fabric (such as Wolfram cloth) that forms the fabric layer 22 of the panel 100.
  • a non-woven fabric such as Wolfram cloth
  • the paste is then poured onto the mould in accordance with a pouring step. Since the paste is highly viscous, it is spread by using manual or automated spreading means to spread the paste around the mould as desired.
  • a reinforcing mesh 25 in the form of a fibreglass mesh is positioned into the mould and the mould is subsequently passed through a first pair of rollers in a first rolling step. The spacing of the rollers in the roller pair is adjusted such that the paste is spread around on the mould to position the reinforcing mesh adjacent to the mould lining.
  • the first rolling step is followed by introducing further paste from the mixing chamber into the mould. Once again the paste is spread by using the spreading means as previously discussed. This is followed by positioning another reinforcing fibreglass mesh and by using the rollers in a second rolling step. The spacing of the rollers may once again be adjusted for spreading the paste uniformly and for positioning the fibreglass mesh within an internal central portion of the core 30. Subsequently, further paste is once again added to the mould and the third reinforcing fibreglass mesh 15 is also introduced in a third rolling step. Therefore, the inclusion of each of the plurality of reinforcing mesh in the board requires a rolling step for positioning the mesh in the core of the panel in accordance with an embodiment of the present invention. Subsequently another fabric layer 12 (Wolfram cloth) may be used as a top surface lining for the panel 100.
  • another fabric layer 12 (Wolfram cloth) may be used as a top surface lining for the panel 100.
  • the paste may be permitted to dry and settle to initially cure the board and the drying time may vary depending on the ambient temperature and humidity.
  • the core may be removed from the mould.
  • the core may be also subjected to a post-curing step that also allows the materials in the composition to further bond.
  • the core may also be trimmed, sanded or finished and cut to the desired dimensions.
  • the next method steps involve the adhesive boding of the outer sheets 60 and 70 onto the core 30 by using a cold pressing method.
  • the process for adhesive bonding the aluminum sheets (260 and 270) or the veneer sheets (360 and 370) is carried out under the cold pressing method.
  • the outer sheets 60 and 70 are bonded to the core 30 by using several processes that utilise a structural adhesive such as The adhesives are applied evenly over the face and back of the core 30 and the outer sheets 60 and 70 by either a hand applicator, roller spreader or a spray nozzle applicator of the core 30 in several stages.
  • a structural adhesive such as The adhesives are applied evenly over the face and back of the core 30 and the outer sheets 60 and 70 by either a hand applicator, roller spreader or a spray nozzle applicator of the core 30 in several stages.
  • a first stage involves the application of a primer binder to both outer surfaces of the core 30 and allow the core to dry. The drying process allows the binder to absorb and lock into the surface of the core 30 creating a consistent surface that will allow for a closer and better binding when the outer sheets 60 and 70 are applied thereon.
  • a second stage involves application of an adhesive that is applied evenly to the core 30 and the outer sheets 60 and 70 and these are then brought together with the outer sheets being applied to the core 30 to form a laminated panel.
  • the laminated panel is then placed in a press to activate the adhesives which bonds the outer sheets 60 and 70 to the core 30 thereby forming the composite panel 100.
  • the panels 100 may be cut and sized in any manner.
  • the above described method may also be utilised to form composite panels 200 to 400.
  • a polyurethane glue specifically PU-50 Double Component type polyurethane glue was used.
  • a polyurethane glue specifically MPU-20 Single Component type polyurethane glue was used.
  • a commercially available polyester based resin namely LS2 01 AB polyester resin was used.
  • Floor panel 300 was subjected to a non-combustibility test, as set out below:
  • fireproof and fire-resistant refer to a substance that is resistant to the effects of fire that is, describing a material that is substantially or completely non- combustible and/or substantially insulating.
  • a construction board or a construction panel is in no way limited to planar structures and encompasses construction members having a non-planar structure. It will be understood that the constructions boards and panels described herein designed to be compatible with standard construction methods and materials.

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Abstract

A composite panel comprising: a core having at least 30wt% magnesium oxide; and at least one outer sheet adhesively bonded to an outer surface of the moulded core.

Description

COMPOSITE PANEL
TECHNICAL FIELD
The present invention relates to composite panels such as composite building panels and a method of building the composite panels. The composite panels may include but not be limited to facade panels, floor panels and wall panels used in the building industry.
BACKGROUND
Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge.
The use of composite panels in the building and construction industry is known. By way of example, composite panels are used for external walls, facades and even floor installations. Depending on their composition, composite panels can exhibit many advantageous features such as being weather proof, noise absorbing, fireproof, light and easy to cut, impact resistant and easy to maintain. The advent of modern building practices through the use of modular construction panels has changed the way panels are used in the construction industry. As a result, construction panels such as fagade panels and floor panels must comply with strict building code regulations for fire resistance. Accordingly, there is a need for providing composite building panels with improved fire-resistance properties.
SUMMARY OF THE INVENTION
In one aspect, the invention comprises a composite panel comprising:
a moulded core having at least 30wt% magnesium oxide; and at least one outer sheet adhesively bonded to an outer surface of the moulded core. In another aspect, the invention comprises a composite panel comprising: a moulded core having at least 30wt% magnesium oxide; and two spaced apart outer sheets for positioning the core therebetween;
wherein each of said outer sheet is adhesively bonded to the moulded core.
In an embodiment, the moulded core comprises at least one reinforcing mesh of a first type positioned in an interior portion of the moulded core.
Preferably, the moulded core further comprises at least one additional reinforcing mesh of a second type positioned in a spaced relationship relative to the at least one reinforcing mesh of the first type.
More preferably, the at least one additional reinforcing mesh of the second type is positioned adjacent the outer surface of the moulded core.
In an embodiment, tensile strength of the reinforcing mesh of the first type is different from tensile strength of the reinforcing mesh of the second type.
In an embodiment, tensile strength of the reinforcing mesh of the second type is lower relative to tensile strength of the reinforcing mesh of the first type.
In an embodiment, at least one of the reinforcing mesh is oriented in the moulded core in a substantially parallel orientation relative to the outer sheets.
In one embodiment each of the outer sheets comprises a sheet thickness, the sheet thickness being less than or equal to a thickness of the core.
In an alternative embodiment, a thickness of at least one of the outer sheets is greater than a thickness of the other of the outer sheets. In some embodiments, thickness of at least one outer sheet may be greater than thickness of the core. In an embodiment, the core comprises less than 60wt% magnesium oxide.
In an embodiment, the moulded core further comprises a binding agent and/or a filling agent.
In an embodiment, the moulded core further comprises a dispersing agent to disperse the contents of the core.
In an embodiment, the outer sheet comprises a metallic sheet.
In an embodiment, the metallic sheet comprises aluminum or aluminum alloys.
In an embodiment, the outer sheet comprises veneer.
In an embodiment, the outer sheet comprises an engineered stone slab or natural stone slab.
In an embodiment, the outer sheet comprises laminate material.
In an embodiment, the moulded core further comprises a fabric layer positioned along at or adjacent an outer portion of the core
In another aspect, the invention comprises a method of manufacturing a composite panel, the method comprising:
forming a moulded core by undertaking the steps of:
preparing a mixture of at least 30 wt% magnesium oxide and at least one binding or filling agent;
adding the mixture into a liquid medium for forming a slurry and introducing the slurry into a mould;
positioning a reinforcing mesh into an internal space of the mould;
pressing the mesh into the slurry contained in the mould; and curing the slurry by a heat treatment step to form the core such that the reinforcing mesh is positioned in an interior portion of the core; applying an adhesive material on one or more of outwardly exposed surfaces of the core; and
pressing an outer sheet onto one of said outwardly exposed surfaces of the core thereby adhesively bonding said outer sheet onto the outwardly exposed surface of the core.
In an embodiment, a respective outer sheet is adhesively bonded to two opposite outer surfaces such that the core is positioned between two outer sheets.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:
Figure 1 is a sectional end view of a composite panel 100 in accordance with a first embodiment.
Figure 2 is a schematic sectional view of the composite panel 100.
Figure 3 is top orthogonal view of a composite panel 200 in accordance with a second embodiment.
Figure 4 is an end view of the composite panel 200.
Figure 5 is a top view of the composite panel 200. Figure 6 is a top orthogonal view of a composite panel 300 in accordance with a third embodiment.
Figure 7 is an end view of the composite panel 300.
Figure 8 illustrates two composite panels 300A and 300B in a disconnected configuration.
Figure 9 illustrates two composite panels 300A and 300B in an interconnected configuration.
Figure 10 is an illustration of two composite panels 400A and 400 in accordance with a fourth embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to Figures. 1 and 2, the present invention relates to a construction board in the form a composite panel 100 that offers a combination of a high degree of fire resistance, a high density, high flexural strength, and effective moisture and water resistance.
The composite panel also comprises two spaced apart outer sheets 60 and 70 for positioning the moulded core 30 there-between. Each of the outer sheets 610 and 70 is adhesively bonded to opposite sides of the moulded core 30. The following sections describe details for the moulded core 30 and the outer sheets 60 and 70 in further detail.
The advantageous properties of the composite panel 100 are attained by a combination of the moulded core 30 sandwiched in between the outer sheets 60 and 70. The moulded core 30 is formulated to include about 30% to about 60% by weight of the magnesium oxide with at least 10% by weight of magnesium chloride. The composite panel may also include magnesium sulphate. The core 30 also incorporates one or more hydrophobic agents. Such hydrophobic agents may be added in order to increase the overall water-resistance of the panel 100. Any suitable hydrophobic agent may also be used during panel manufacture. The core material further comprises additives such as a binding agent like cellulose (at least % to about 20% by weight), perlite (preferably 6- 12% by weight) and dispersants. The combination of these core mixtures ingredients yield a panel core 30 that contributes to the enhanced flexural strength of the resulting panel 100. The core material 30 may incorporate one or more fillers that serve to lower the weight of the panel.
The moulded core 30 comprises reinforcing mesh 15 and 25 are also provided within the moulded core 30. Specifically, additional mesh 15 is positioned adjacent to the first outer surface (or top surface) 10. Similarly, additional mesh 25 is positioned adjacent to the second outer surface (bottom surface) 20. The mesh 15, 25 and 50 are arranged in a mutually parallel configuration and are substantially co-parallel with the plane of the first and second opposite outer surfaces 10 and 20.
It is important to appreciate that the present embodiment provides a configuration whereby, the combination of the inwardly located mesh 50 and the outwardly located mesh 15 and 25 improves the overall structural performance of the panel 100 during use. Furthermore still, a pair of non- woven fabric sheets 12 and 22 is also included in between the additional reinforcing mesh (15 and 25) and the respective outer surfaces (10 and 20). At least a part of the outer surface of the moulded core 30 is positioned contiguously with the outer sheets 60 and 70 so that the fabric sheets 12 and 22 lie in close proximity to the outer sheets 60 and 70. The inventors have surprisingly found that positioning the fabric sheets 12 and 22 in the aforementioned configuration assists with improving the in-use characteristics of the composite panel 100.
The outer sheets 60 and 70 may comprise a metallic material such aluminium or aluminium containing alloy. The outer sheets 60 and 70 are adhesively bonded to opposite outer surfaces of the moulded core 30 to form the composite panel 100. The inventors have found that positioning each of the outwardly located reinforcing mesh 15 and 25 in the moulded core 30 in close proximity to the outer sheets 60 and 70 provides an unexpected and significant improvement in structural flexural strength of the composite panel 100.
Referring to Figures 3 to 5 another embodiment in the form of a composite panel 200 illustrated. The composite panel comprises a core 230 which possesses substantially similar characteristics as the core 230 which has been described in previous sections. The core 230 is laminated on opposite surfaces with flat sheets of aluminium (260 and 270) that have a thickness in the range of 0.5 to 0.7 gauge. As discussed in previous sections, the flat sheets of aluminium (260 and 270) are adhesively bonded to the opposite surfaces of the core 230. The composite panels 200 are particularly useful for use as cladding panels or facade panels that can be readily fastened to an outwardly facing wall of a building. The panels 200 are light-weight and fire resistant and provide a much improved alternative to existing cladding panels that are currently available. Each of the outer sheets 260 and 270 have a similar thickness that is substantially less than the thickness of the core 230.
Referring to Figures 6 to 9 another embodiment in the form of a composite floor panel 300 is illustrated. The composite panel comprises a core 330 which possesses substantially similar characteristics as the core 330 which has been described in previous sections. The core 330 is laminated on opposite surfaces with flat sheets of veneer (360 and 370) that have a thickness in the range of 0.5 to 0.7 gauge. As discussed in the previous sections, the flat sheets of veneer (360 and 370) are adhesively bonded to the opposite surfaces of the core 330. The composite panels 300 are particularly useful for use as flooring panels. Referring to Figures 8 and 9 in particular, panels 300A and 300B may be provided with an inter-locking arrangement provided along an edge portion of each panel 300A and 300B for inter-locking the panels 300A and 300B during use. Each of the outer sheets 360 and 370 have a similar thickness that is substantially less than the thickness of the core 330.
Referring to Figure 10, yet another embodiment in the form of a composite panel 400 is illustrated. The composite panel also comprises a core 430 which possesses substantially similar characteristics as the core 430 which has been described in previous sections. The core 430 is laminated on opposite surfaces with flat sheets of two different materials. A first outer sheet of veneer 470 is positioned on a first outer face of the core 430 and a second sheet 460 (having a greater thickness relative to the first sheet 470). The second sheet 460 may comprise of any material other than veneer.
The passages below describe one of many possible methods which may be utilised for moulding the core 30 of the composite panel 100 for the preferred embodiment. The method includes a plurality of steps, which will be described below in detail. The order of least some of the steps may be varied from that shown and at least some of the actions may be performed sequentially or concurrently. The constituents forming the moulded core 30 are in accordance with the amounts as described previously.
A dry mixing step is carried out in which at least the magnesium oxide, the magnesium chloride and the perlite is mixed to obtain a homogenised dry mixture. The magnesium oxide, magnesium chloride and perlite ingredients are initially mixed to form a dry powdery mixture. In at least some embodiments, 30% to about 60% by weight of the magnesium oxide, about at least 10% by weight of the magnesium chloride and about 6-12% by weight of perlite is mixed. The binding agent provided in the form of alpha cellulose functions to bind the composition together and may also comprise further additives.
The method includes mixing the dry powder with water in a mixing chamber in a slurry preparation step. Tap water may be used. The water solution may be stirred periodically over a period of time, by stirring means. The mixing results in the formation of a slurry 630 with a past like consistency or viscosity.
The next step comprises lining the mould with a non-woven fabric (such as Wolfram cloth) that forms the fabric layer 22 of the panel 100. After the paste has settled in the mixing chamber, the paste is then poured onto the mould in accordance with a pouring step. Since the paste is highly viscous, it is spread by using manual or automated spreading means to spread the paste around the mould as desired. After the spreading step, a reinforcing mesh 25 in the form of a fibreglass mesh is positioned into the mould and the mould is subsequently passed through a first pair of rollers in a first rolling step. The spacing of the rollers in the roller pair is adjusted such that the paste is spread around on the mould to position the reinforcing mesh adjacent to the mould lining.
The first rolling step is followed by introducing further paste from the mixing chamber into the mould. Once again the paste is spread by using the spreading means as previously discussed. This is followed by positioning another reinforcing fibreglass mesh and by using the rollers in a second rolling step. The spacing of the rollers may once again be adjusted for spreading the paste uniformly and for positioning the fibreglass mesh within an internal central portion of the core 30. Subsequently, further paste is once again added to the mould and the third reinforcing fibreglass mesh 15 is also introduced in a third rolling step. Therefore, the inclusion of each of the plurality of reinforcing mesh in the board requires a rolling step for positioning the mesh in the core of the panel in accordance with an embodiment of the present invention. Subsequently another fabric layer 12 (Wolfram cloth) may be used as a top surface lining for the panel 100.
The paste may be permitted to dry and settle to initially cure the board and the drying time may vary depending on the ambient temperature and humidity. Once the core has dried, the core may be removed from the mould. The core may be also subjected to a post-curing step that also allows the materials in the composition to further bond. The core may also be trimmed, sanded or finished and cut to the desired dimensions.
The next method steps involve the adhesive boding of the outer sheets 60 and 70 onto the core 30 by using a cold pressing method. The process for adhesive bonding the aluminum sheets (260 and 270) or the veneer sheets (360 and 370) is carried out under the cold pressing method.
The outer sheets 60 and 70 are bonded to the core 30 by using several processes that utilise a structural adhesive such as The adhesives are applied evenly over the face and back of the core 30 and the outer sheets 60 and 70 by either a hand applicator, roller spreader or a spray nozzle applicator of the core 30 in several stages.
A first stage involves the application of a primer binder to both outer surfaces of the core 30 and allow the core to dry. The drying process allows the binder to absorb and lock into the surface of the core 30 creating a consistent surface that will allow for a closer and better binding when the outer sheets 60 and 70 are applied thereon. A second stage involves application of an adhesive that is applied evenly to the core 30 and the outer sheets 60 and 70 and these are then brought together with the outer sheets being applied to the core 30 to form a laminated panel.
The laminated panel is then placed in a press to activate the adhesives which bonds the outer sheets 60 and 70 to the core 30 thereby forming the composite panel 100. The panels 100 may be cut and sized in any manner.
The above described method may also be utilised to form composite panels 200 to 400.
In one embodiment, a polyurethane glue, specifically PU-50 Double Component type polyurethane glue was used.
In another embodiment, a polyurethane glue, specifically MPU-20 Single Component type polyurethane glue was used.
In one exemplary embodiment a commercially available polyester based resin, namely LS2 01 AB polyester resin was used.
Main ingredients:
Figure imgf000011_0001
Figure imgf000012_0001
Floor panel 300 was subjected to a non-combustibility test, as set out below:
Figure imgf000012_0002
Figure imgf000013_0001
Figure imgf000014_0001
Figure imgf000015_0001
Figure imgf000016_0001
Figure imgf000017_0001
As used herein, the terms "fireproof and "fire-resistant" refer to a substance that is resistant to the effects of fire that is, describing a material that is substantially or completely non- combustible and/or substantially insulating. A construction board or a construction panel is in no way limited to planar structures and encompasses construction members having a non-planar structure. It will be understood that the constructions boards and panels described herein designed to be compatible with standard construction methods and materials.
In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term "comprises" and its variations, such as "comprising" and "comprised of" is used throughout in an inclusive sense and not to the exclusion of any additional features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.
Throughout the specification and claims (if present), unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms.
Any embodiment of the invention is meant to be illustrative only and is not meant to be limiting to the invention. Therefore, it should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the spirit and scope of the invention.

Claims

1 . A composite panel comprising:
a moulded core having at least 30wt% magnesium oxide; and at least one outer sheet adhesively bonded to an outer surface of the moulded core.
2. A composite panel comprising:
a core having at least 30wt% magnesium oxide; and two spaced apart outer sheets for positioning the moulded core there-between;
wherein each of said outer sheet is adhesively bonded to the moulded core.
3. A composite panel in accordance with claim 1 or claim 2 wherein the moulded core comprises at least one reinforcing mesh of a first type positioned in an interior portion of the moulded core.
4. A composite panel in accordance with claim 3 wherein the moulded core further comprises at least one additional reinforcing mesh of a second type positioned in a spaced relationship relative to the at least one reinforcing mesh of the first type.
5. A composite panel in accordance with claim 4 wherein the at least additional reinforcing mesh of the second type is positioned adjacent one of said outer sheets.
6. A composite panel in accordance with claim 4 or claim 5 wherein tensile strength of the reinforcing mesh of the first type is different from tensile strength of the reinforcing mesh of the second type.
7. A composite panel in accordance with claim 6 when dependent upon claim 5 wherein tensile strength of the reinforcing mesh of the second type is lower relative to tensile strength of the reinforcing mesh of the first type.
8. A composite panel in accordance with any one of claims 2 to 7 wherein at least one of the reinforcing mesh is oriented in a substantially parallel orientation relative to the outer sheets.
9. A composite panel in accordance with any one of the preceding claims wherein each of the outer sheets comprises a sheet thickness, the sheet thickness being less than or equal to a thickness of the moulded core.
10. A composite panel in accordance with any one of the preceding claims wherein the moulded core comprises less than 60wt% magnesium oxide.
1 1 . A composite panel in accordance with any one of the preceding claims wherein the moulded core further comprises a binding agent and/or a filling agent.
12. A composite panel in accordance with any one of the preceding claims wherein the moulded core further comprises a dispersing agent to disperse the contents of the moulded core.
13. A composite panel in accordance with any one of the preceding claims wherein the outer sheet comprises a metallic sheet.
14. A composite panel in accordance with claim 13 wherein the metallic sheet comprises aluminium or aluminium alloys.
15. A composite panel in accordance with any one of claims 1 to 13 wherein the outer sheet comprises veneer.
16. A composite panel in accordance with any one of claims 1 to 12 wherein the outer sheet comprises an engineered stone slab or natural stone slab.
17. A composite panel in accordance with any one of claims 1 to 12 wherein the outer sheet comprises laminate material.
18. A composite panel in accordance with any one of the preceding claims wherein the moulded core further comprises a fabric layer positioned along at or adjacent an outer portion of the moulded core
19. A method of manufacturing a composite panel, the method comprising: forming a moulded core by undertaking the steps of:
preparing a mixture of at least 30 wt% magnesium oxide and at least one binding or filling agent;
adding the mixture into a liquid medium for forming a slurry and introducing the slurry into a mould;
positioning a reinforcing mesh into an internal space of the mould;
pressing the mesh into the slurry contained in the mould; and curing the slurry by a heat treatment step to form the moulded core such that the reinforcing mesh is positioned in an interior portion of the moulded core;
applying an adhesive material on one or more of outwardly exposed surfaces of the moulded core; and
pressing an outer sheet onto one of said outwardly exposed surfaces of the core thereby adhesively bonding said outer sheet onto the outwardly exposed surface of the moulded core.
20. A method in accordance with claim 19 wherein a respective outer sheet is adhesively bonded to two opposite outer surfaces such that the moulded core is positioned between two outer sheets.
PCT/AU2018/050381 2017-04-28 2018-04-27 Composite panel WO2018195599A1 (en)

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