Patent EA-004094-B1 (EA)
Title: Improvements to modular buildings, construction elements, methods and materials therefor
Inventor: PARRISH MALCOLM
IPC: B29C70/66
Filed: 2001-04-18
Abstract: 1. A construction element such as a wall or roof panel for a building, the construction element being formed from a composite material comprising silica cenospheres and a resin, the resin binding the cenospheres into a solid mass and retains them in a desired shape defining the construction element. 2. A construction element according to claim 1, in which the panel includes at least one channel or duct formed therein parallel to a longitudinal axis thereof and at least one channel or duct formed therein perpendicular to and laterally of the longitudinal axis. 3. A construction element according to claim 1 or claim 2, 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. 4. A construction element according to claim 3, in which the thickness of the nylon layers is between17-21 urn, so that the nylon layers neither tear nor distort during processing. 5. A construction element according to either claim 3 or 4, in which the resin is present in an amount of 30-50% w/w of the second composite material. 6. A construction element according to claim 5, 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. 7. A construction element according to any one of claims 1 to 6, in which there is provided a fire retardant material. 8. A construction element according to claim 7, in which the fire retardant material is included between the nylon layers. 9. A construction element according to claim 7 or claim 8, in which the fire retardant material is selected from aluminium trioxide, glass flakes or a retardant chemical such as polyhalogenated phenols including bromophenols. 10. A construction element according to claim 9, in which aluminium trioxide is provided in an amount 15-50% w/w with respect to the resin. 11.A construction element according to claim 10, in which the aluminium trioxide is present in an amount 30-40% w/w. 12. A construction element according to any one of claims 3 to 11, in which the second composite material includes a glass-tissue layer having a density of 14-30 g/m<2>, to reduce uneven features being introduced to the surface thereof. 13. A construction element according to any one of claims 3 to 12, in which the second composite material includes a colouring agent such as titanium dioxide to improve its appearance. 14. A method of manufacturing a construction element from a composite material including cenospheres, the method including the steps of : distributing cenospheres within a resin monomer to form a mixture ; distributing a polymerisation catalyst within the mixture; pouring the mixture into a mould defining the desired shape of the construction element; and removing the polymerised element from the mould. 15. A method of manufacturing a construction element according to claim 14, 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. 16. A method of manufacturing a construction element according to claim 14 or claim 15, in which the polymerisation catalyst is selected from hexamine or methylethyl ketone peroxide. 17. A method of manufacturing a construction element according to any one of claims 14 to 16, in which the catalyst is supported on an inert matrix to slow down or delay the polymerisation process. 18. A method of manufacturing a construction element according to claim 17, in which the inert matrix is a clay such as bentonite. 19. A method of manufacturing a construction element according to any one of claims 14 to 18, in which the method includes passing ultrasound through the mixture. 20. A method of manufacturing a construction element according to any one of claims 14 to 19, 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. 21. A method of manufacturing a construction element according to any one of claims 14 to 20, 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. 22. A method of manufacturing a construction element according to any of claims 14 to 21, 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. 23. A method of manufacturing a construction element according to claim 22, in which the thickness of the nylon layers is between 17-21mum, so that the nylon layers neither tear nor distort during processing. 24. A method of manufacturing a construction element according to either claim 22 or 23, in which the resin is present in an amount of 30-50 % w/w of the second composite material. 25. A method of manufacturing a construction element according to any of claims 22 to 25, 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. 26. A method of manufacturing a construction element according to any one of the preceding claims, in which there is provided a fire retardant material. 27. A method of manufacturing a construction element according to claim 26, in which the fire retardant material is included between the nylon layers. 28. A method of manufacturing a construction element according to claim 26 or claim 27, in which the fire retardant material is selected from aluminium trioxide, glass flakes or a retardant chemical such as polyhalogenated phenols including bromophenols. 29. A method of manufacturing a construction element according to claim 28, in which aluminium trioxide is provided in an amount 15-50% w/w with respect to the resin. 30. A method of manufacturing a construction element according to claim 29, in which the aluminium trioxide is present in an amount 30-40 % w/w. 31. A method of manufacturing a construction element according to any one of claims 22 to 31, in which the second composite material includes a glass-tissue layer having a density of 14-30 g/m<2>, to reduce uneven features being introduced to the surface thereof. 32. A method of manufacturing a construction element according to any one of claims 22 to 31, in which the second composite material includes a colouring agent such as titanium dioxide to improve its appearance. 33. A modular building comprising construction elements as defined in claim 1. 34. A method of constructing a building including the steps of preparing: a ground area on which the building is to stand to receive a foundation floor; forming a foundation floor having secured therein a plurality of anchor elements; securing wall-retaining members to the foundation floor over said anchor elements, to define the location of load bearing walls; attaching elongate securing members to the anchor elements; locating wall panels, having one or more securing member receiving channels, with respect to the wall-retaining members; securing wall panels by threading the flexible securing members through the wall panels; tensioning said securing members; and locking the securing members to attenuate movement. 35. A construction element, substantially as herein described with reference to and as shown in the accompanying drawings. 36. A method of manufacturing a construction element substantially as herein described with reference to the accompanying drawings. 37. A modular building, substantially as herein described with reference to and as shown in the accompanying drawings. 38. A method of constructing a building utilising composite material construction elements, substantially as herein described with reference to the accompanying drawings.