Patent EA-004964-B1 (EA)
Title: Composite material for construction of modular buildings
Inventor: PARRISH MALCOLM
IPC: C04B26/02
Filed: 2001-04-18
Abstract: 1. A composite material comprising silica cenospheres and a resin, whereby the resin is adapted to bind the cenospheres into a solid mass and retain them in a desired shape into which the composite material is to be formed. 2. A composite material according to claim 1, in which the resin is present in an amount from 2-10% w/w. 3. A composite material according to claim 2, in which the amount of resin present is from 4-6% w/w. 4. A composite material according to any of claims 1 to 3, in which the resin is selected from one or more of the following classes of polymeric compounds: polyester; polyurethane; polyacrylic; polyphenolic; polybromophenolic; polyvinylester; or epoxy resins including mixtures thereof. 5. A composite material according to any one of the preceding claims, in which the silica cenospheres include a plurality of air-spaces to minimise the weight of each cenosphere, thereby reducing the mass of any article formed using said composite material. 6. A composite material according to any one of the preceding claims, in which cenospheres of differing diameters are used to maximise the packing efficiency of said cenospheres within the composite material. 7. A composite material according to any one of the preceding claims, in which the diameter of the cenospheres is from 0.5mm to 8mm. 8. A composite material according to claim 6 or claim 7, in which a distribution of 2mm, 1mm and 0.5mm diameter cenospheres in a w/w ratio of 3: 2: 1 is selected. 9. A method of manufacturing a composite material product utilising silica cenospheres, the method including: distributing cenospheres within a resin monomer to form a mixture; distributing a polymerisation catalyst within the mixture; pouring the mixture into a mould; and removing the polymerised product from the mould. 10. A method of manufacturing a composite material product according to claim 9, in which the monomer is selected from an unsaturated ester such as a vinyl ester, an epoxy compound, or an unsaturated hydrocarbon, to give a strong yet partially flexible composite product. 11. A method of manufacturing a composite material product according to claim 9 or claim 10, in which the polymerisation catalyst is selected from hexamine or methylethyl ketone peroxide. 12. A method of manufacturing a composite material product according to any one of claims 9 to 11, in which the catalyst is supported on an inert matrix to slow down or delay the polymerisation process. 13. A method of manufacturing a composite material product according to claim 12, in which the inert matrix is a clay such as bentonite. 14. A method of manufacturing a composite material product according to any one of claims 9 to 13, in which the method includes passing ultrasound through the mixture. 15. A method of manufacturing a composite material product according to any one of claims 9 to 14, in which the method includes vibration of the mixture during the polymerisation process to reduce any separation due to different density of the components or due to any phase changes which may take place so as to give a consistent product. 16. A method of manufacturing a composite material product according to any one of claims 9 to 15, in which the method includes physically drawing the mixture into the mould so as to reduce the number of air pockets in the finally formed product. 17. A construction element such as a wall or roof panel for a modular building, the construction element comprising a composite material as defined in claim 1. 18. A construction element according to claim 17, in which bonded to and across at least part of a surface thereof, there is provided a second composite material comprising a plurality of layers, including inner and outer nylon layers, a glass fibre mat layer therebetween and a polymer resin distributed between the nylon layers to bond the layers together. 19. A construction element according to claim 18, in which the thickness of the nylon layers is between 17-21mum, so that the nylon layers neither tear nor distort during processing. 20. A construction element according to either claim 18 or 19, in which the resin is present in an amount of 30-50% w/w of the second composite material. 21. A construction element according to any one of claims 18 to 20, in which the resin is selected from one or more of the following classes of polymeric compounds: polyester; polyurethane; polyacrylic; polyphenolic; polybromophenolic; polyvinylester; or epoxy resins, including mixtures thereof. 22. A construction element according to any one of claims 17 to 21, in which there is provided a fire retardant material. 23. A construction element according to claim 22, in which the fire retardant material is included between the nylon layers. 24. A construction element according to claim 22 or claim 23, in which the fire retardant material is selected from aluminium trioxide, glass flakes or a retardant chemical such as polyhalogenated phenols including bromophenols. 25. A construction element according to claim 24, in which aluminium trioxide is provided in an amount 15-50%w/w with respect to the resin. 26. A construction element according to claim 25, in which the aluminium trioxide is present in an amount 30-40%w/w. 27. A construction element according to any one of claims 18 to 26, in which the second composite material includes a glass-tissue layer having a density of 14-30g/m2, to reduce uneven features being introduced to the surface thereof. 28. A construction element according to any one of claims 18 to 27, in which the second composite material includes a colouring agent such as titanium dioxide to improve its appearance. 29. A composite material comprising silica cenospheres and a resin, substantially as herein described with reference to the accompanying drawings. 30. A method of manufacturing a composite material product utilising cenospheres, substantially as herein described with reference to the accompanying drawings. 31. A composite material product substantially as herein described with reference to and as shown in the accompanying drawings. 32. A construction element substantially as herein described with reference to and as shown in the accompanying drawings.