Patent Application
20160009046
The present invention relates to a material, more particularly to a multi-layered material suitable for making sheet products which can have a variety of uses, including being formed into tubing used in a range of applications including forming concrete columns. The present invention also relates to a formwork or construction made from such a material, for use as a building or construction element or in forming a building element such as a column or pier. The formwork or construction element can be wound by known techniques such as spiral winding or other winding techniques.
Multi-layered materials such as multi-layered paper constructions have been used to manufacture construction products, such as the paper tubing used for forming concrete columns. A potential problem involved in using paper tubing for forming concrete columns involve, for example, a weakening of the paper tubing as the paper or cardboard material becomes wetted. It is also desirable to increase the tensile strength and burst pressure of the tubing.
Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application.
The present invention provides a formwork or construction element tube having multiple layers which include at least two layers comprised of a multi-layered sheet material, each of said multi-layered sheet material including at least one non-woven filament layer that includes a plurality of reinforcing filaments, each of said multi-layered sheet material also including said non-woven filament layer being bonded or adhered to at least one layer of paper, cardboard or polymer.
The multiple layers can also include at least one layer of paper, cardboard or polymer between said at least two multi-layered sheet materials.
The multi-layered sheet material can each have a multiple number of non-woven filament layers.
The tube can be formed by one or more than one of the following means: an adhesive is used to bond said multiple layers together into said tube; a heat bonding process is used to bond said multiple layers together into said tube; said multiple layers are spirally wound; said multiple layers are cylindrically or straight wound; said multiple layers are wrapped.
There can be at least three layers of said multi-layered sheet material, and at a location intermediate an inner and outer layer of said multi-layered sheet material is located said at least one layer of paper, cardboard or polymer, each layer being bonded by an adhesive layer or other means.
The tube can include at least one layer which is a hydrophobic layer or a waterproofing layer. The at least one layer of said hydrophobic layer or a waterproofing layer can be located at one or more than one of the following: an innermost layer of said tube, an outermost layer of said tube; an intermediate layer of said tube.
The filaments can extend in one of the following directions: in the general longitudinal direction of said multi-layered sheet material; at an angle to the general longitudinal direction of said multi-layered sheet material; if more than one then a first in the general longitudinal direction and another at an angle in the range of 5 to 90 degrees to the general longitudinal direction of said multi-layered sheet material.
The filaments can be one or more of the following: strips; ribbons, straps; strands; tapes; said filaments are spaced from each other in said non-woven filament layer; polymeric; fibreglass; metal wire filaments; polypropylene; polyethylene; a polypropylene and polyethylene blend; polyester; or a blend of polymers.
When assembled in said tube, a first non-woven filament layer can have its directional strength characteristics at an angle to a second non-woven filament layer
The present invention also provides a multi-layered material, including at least one non-woven strength layer, and a layer of paper, cardboard or polymer, the layers being bonded together.
The non-woven strength or reinforcing layer can be a full width strength layer, alternatively it can be a filament layer which includes a plurality of strips, tapes, strands, or straps, in the form of filaments.
The filament layer can include filament which run in a longitudinal direction of the multi-layered material, or in a direction that is at about a 5 to 90 degree angle to the longitudinal direction.
The non-woven strength layer can be a combination of full width and filament layers.
The multi-layered material can include at least two non-woven strength layers being: (a) a full width strength layer and a layer of filaments, (b) two full width strength layers, or (c) two layers of filaments.
The layer of filaments can include a plurality of strips, straps, strands, or tapes of filaments, the strips or tapes being spaced from each other.
Multiple layers of filaments can be present in the strength layers, wherein the adjacent layers can overlap or overlie each other.
The strips or tapes of filaments from one non-woven strength layer can overlie spacing between filament strips or tapes of the other non-woven strength layer.
Filaments in the non-woven strength layer can be polymeric, fibreglass, or metal wire filaments, or a combination of these.
When the filaments are of a polymeric material, the material can be polypropylene, polyethylene, a polypropylene and polyethylene blend, or polyester.
The layer of paper, cardboard or polymer can be paper, and can weigh 20 grams per square meter or more.
The multi-layered material can further include a coating on either or both of the non-woven strength layer and layer of paper, cardboard or polymer.
The coating can be food grade.
The multi-layered material can further include another paper layer that is bonded to the layer of paper, cardboard or polymer, the layer or paper, cardboard or polymer and the other paper layer being bonded together by a waterproof adhesive film.
The waterproof adhesive film can be food grade.
The multi-layered material can further include two or more non-woven strength layers, there being at least one layer of paper, cardboard, or polymer, or a coating layer, between each adjacent two of the two or more non-woven strength layers.
The filaments can be multi-strand filaments.
The filaments can run in a roll direction of the multi-layered material.
The multi-layered material can further include an adhesive film as an outer layer.
One or both outer layers can be paper, or polymeric material.
A second non woven strength layer can be adhered or bonded so that a directional strength characteristic of the second non-woven strength layer is at an angle to a directional strength characteristic of a first non-woven strength layer.
The second non woven strength layer can be a filament layer and this can be at an angle to a first filament layer.
A layer of cardboard, paper or polymer can be between said first and second layer.
The first layer can be located between a layer of cardboard, paper or polymer and second layer.
The second layer can have its directional strength characteristics at an angle of between 5 and 90 degrees to said first layer.
The multi-layer material described above can be such that a first of said non woven strength layers is arranged in said material so that a directional strength characteristic of said first layer, is parallel to the roll or machine or longitudinal direction of said material, and said second layer has its directional strength characteristic is at an angle thereto, and that angle can be in the range of 0 to 90 degrees.
The multi-layer material described above can be such that there is only one non woven strength layer and that layer has a directional strength characteristic, or filaments or straps thereof, which is or are aligned in a manner which is one of the following: generally parallel to the roll or machine or longitudinal direction of said material; generally lateral to the roll or machine or longitudinal direction of said material, i.e. a cross direction; at an angle other that of parallel to or at 90 degrees to the roll or machine or longitudinal direction of said material.
The present invention also provides a tube formed from spiral winding a multi-layered material as described in the paragraphs above.
An embodiment or embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
Multi-layered paper or cardboard materials can be used in the field of construction and manufacturing, for example, to be used as the tubing for forming concrete columns. The multi-layered material can also be used as, for example, carpet underlay or lumber packaging material, concrete lining, protective layers and strengtheners of packaging products.
The present technology provides an improved multi-layered construction for the multi-layered material. As shown in
As is described below, further layers can be added to form other variations as depicted in
Several embodiments are illustrated in the accompanying drawing figures. The different embodiments can be used for constructing packaging or tubing of different tensile strengths, thicknesses, and weights.
In the embodiments depicted in
In
A specific example of such filaments are those ribbons or flat strands that are made of 100% virgin polypropylene, having a width of approx 2.5 mm and a thickness of approx. 0.02 mm to 0.05 mm, having a fibre tenacity or detex of approx 900 to 1000, a tensile strength of greater than or equal to 45N, an elongation of greater than or equal to 30%, and when wound on a 105 mm bobbin provides a length of approx 12000 m. If desired a thicker filament 110.1 etc. could be used, of the order of 0.05 mm to 0.07 mm or even up to 1 mm and but this may require the use of a thicker coating of adhesive to provide a more rigid product for various applications. However, the preferred thickness for formwork application is of the order of 0.02 mm to 0.05 mm. Thickness of filament can also vary according to the tensile strength characteristic of the material being used.
The filament layer 110 can alternatively be made of fibreglass, wire filaments, or any appropriate metal. The filament material that is chosen is dependent on the requirements for the finished product. In instances where the multi-layered material is to form a roll or tubing, the filaments generally run in the direction of the roll, marked by ‘D’. Also, the filaments can have different cross sections, such as round, oval, or any other appropriate cross section. The resulting roll is preferably presented as having straight edges, without any significant telescoping, creasing, and having no joins.
The filament layer 110 can include high strength filaments arranged in tapes, ribbons, cords, straps, or strands which extend in a longitudinal direction of the material. There can be at least about 5 to 7 tapes or filaments of 2 mm to 2.5 mm width per 25 mm of width of the sheet material. Alternatively, the tapes or filaments can be approximately 1 to 2 mm in width, with 1 to 2 mm spacing between the edges of adjacent tapes or filaments. More preferably, the filaments, ribbons or tapes in the non-woven strength layer 110 are of an average width of 2 mm with 1 mm spacing between adjacent edges.
There can be a layer located between the cardboard layer 105 and the filament layer 110, being a coating or adhesive layer 115 which bonds the two other layers 105, 110 together. The adhesive coating layer 115 can include various resins, such as polymer resins, water or solvent based adhesives which can be heat activated, or heat activated variant polymers, or a resin or adhesive can be used which creates a sealing bond can be used to give the tube a hydrophobic property. As an example, the coating layer 115 which is located between the cardboard layer 105 and the filament layer 110 can be about 30 to 40 μm in thickness. However, in embodiments where the coating layer 115 is not an adhesive layer, the overall layered structure can be produced by being heat bonded, whereby the filament layer 110 has a polypropylene or polyethylene upper and lower layers which sandwich the filament layer.
The filament layer 110 can further have another layer of coating 120, for example about 40 to 45 μm in thickness. The coating layer 120 can be polypropylene, polyethylene, or a polypropylene and polyethylene blend, or another polymer variant. The coating layer 120 can be a coloured coating. Also the coating layer 120 can be hydrophobic or hydrophilic, depending on the application and intended use of the multi-layered material.
As an example, a multi-layered material 100 as discussed above can have a nominal thickness of about 0.30 to 0.40 mm, and a mass of around 235 GSM. Initially, the multi-layered material 100 thus constructed can be formed into widths of approximately 2.4 metres, and formed into another roll, which can be cut or slit and rewound to desired lengths and widths. A preferred roll about 152 to 175 mm in width, and 1000 m or more in length, can be used with existing spiral winding machines, to form a spiral wound tubing of any appropriate internal diameter, for concrete formwork. Typical diameters range between 250 mm and 2000 mm. If a paper layer of about 105 GSM is used, the resulting tubing having two layers of the sheet material 100 and two alternating layers of kraft paper, is expected to have a burst strength in a radial direction of the tubing of about 700 KPa or higher.
The coating layer 120 can have a bonding function or not. Where it has the same or a similar composition and function as the other coating layer 115, it enables further layers to be bonded to the multi-layered material 100. Therefore, the multi-layered material 100 depicted in
Thus the basic sheet material can be considered to be a filament layer 20 or 110, which is bonded to a paper, cardboard or polymeric layer 15 or 25 in the case of layer 20; or a paper, cardboard or polymeric layer 120 or 105 in the case of layer 110.
As shown in
As an example, a multi-layered material 200 as depicted in
The multi-layered material 400 depicted in
The multi-layered material 500 depicted in
The cardboard, kraft paper, or polymeric layer assist with future bonding of the multi-layered material into spiral wound tubes, by either adhesive or other bonding means.
The multi-layered material 600 depicted in
The multi-layered material 700 depicted in
The multi-layered material 800 depicted in
The multi-layered material 900 depicted in
The multi-layered materials 800, 900 depicted in
The multi-layered material 1000 depicted in
The multi-layered material 1100 depicted in
The multi-layered material 1200 depicted in
The multi-layered material 1300 depicted in
The multi-layered material 1400 depicted in
The multi-layered material 1500 depicted in
In the above embodiments, the filament layers are shown as having filaments which run in the roll or machine direction, i.e. longitudinal direction, of the material. However, it is possible for a multi-layered material made from the principles of the present invention to include a filament layer where the filaments run in a different direction, ranging between about 5 to 90 degrees from the machine direction. The cross direction is directed at 90 degrees to the machine direction, i.e. transverse to the direction of the roll.
Illustrated in
It will be understood that the basic multi-layer material 100, comprised of layers 1605, 160 and 1615 form the basic strength element to which can be added other layers as desired or preferred. In the case of the embodiment of
The feature of one non woven strength layer being at an angle to a second non woven strength layer can also be exercised with respect to non-filament layers, i.e. to full width non woven strength layers, in that if such layers have a directional strength characteristic, then the directions of strength can be oriented such that one layer is at an angle to another layer.
Illustrated in
It will be understood that the basic multi-layer material 100, comprised of layers 2320 and 2315 which forms the basic strength element to which can be added other layers as desired or preferred. In the case of the embodiment of
In the embodiment of
Tables 1 to 6 shows test results of stretching and bursting of different samples of the multiple layered structure, to measure the tensile and burst strengths of the materials.
Tables 1 to 3 list the testing results for five samples of a multi-layered structure, having a kraft paper layer of approximately 105 GSM with a 40 to 45 μm polymeric (polypropylene/polyethylene) coating which was heat bonded, and a high tensile polypropylene polymer filament layer, as illustrated in the
The samples for the machine direction tensile testing had a gauge length of 200 mm. The samples for the cross direction tensile testing had a gauge length of 100 mm. During the testing recorded in Table 1, the rate of extension used was 20 mm/min. “Elongation” is the maximum percentage of elongation of the sample before the sample ruptured.
For the tests recorded in Table 2, the samples for both the machine direction tensile and cross direction tensile testing had a gauge length of 100 mm. The rate of extension used was 50 mm/min.
Tables 4 to 6 list the testing results for five samples of another multi-layered structure, having an inner layer of high tensile polypropylene polymer filament, and on either side of the polymer a kraft paper outer layer of approximately 105 GSM, as in the
In the tests recorded in table 4, the samples for the machine direction tensile testing had a gauge length of 200 mm. The samples for the cross direction tensile testing had a gauge length of 100 mm. The rate of extension used was 20 mm/min.
For the tests recorded in Table 5, the samples for both the machine direction tensile and cross direction tensile testing had a gauge length of 100 mm. The rate of extension used was 50 mm/min.
In all of the above embodiments, some or all of the paper layers can be replaced with polymeric layers.
Any two or more of the above embodiments, or variants of the above embodiments, can be bonded together to form further variations.
In the above embodiments, the aluminium sheet/film layers can be replaced with other metallic layers, provided the metal chosen possesses the qualities (e.g. sufficient tensile strength against stretching) for forming sheets or films, to be applied in the situations contemplated herein.
While the above description generally describes a single layer of filaments 110, it will be readily understood that multiple layers of filaments 110 can be utilised. Another advantage of this material is that it is a recyclable material.
In the above embodiments, the coating layers and the polymer blend films can alternatively be food grade coatings and film respectively, or where available, polymeric coatings and film that are food grade. This enables application of the multi-layered materials in food packaging, for domestic or commercial quantities of food stuffs. The food packaging can be in cylindrical or box form.
In the process of spiral winding the multi-layered materials, there can be different ways of bonding the materials to form the tubing. For instance, lines of glue can be combed across the full width of the material. Variations having cardboard or paper outer layers are suited for this form of bonding.
An alternative way is to use a heat bonding attachment in the spiral winding machine to enable heat bonding across the entire width of the material. Variations of the multi-layered material having polymeric outer layers are suitable for heat bonding. By avoiding for example, a water based glue, and not having paper outer layers, the resulting product is water proof rather than merely water resistant, making the resulting tube suitable for a wider range of applications. For instance waterproof formwork tube can be suitable for use as part of reinforcing piers that are submerged in water, or for forming piers under water. If part of the process, then a wound or spirally wound tube can be placed around an existing pier and grout or similar material can be pumped between the internal surface of the tube and the pier. In such cases a split along the outer circumference of the tube may be needed if it is desired to remove the tube once the grout is set. Also, as the bonding interface does not have porosity, the resulting product may also be useful to be used as sanitary packing products. Nevertheless, heat bonding may also be applied where the multi-layered material includes paper or cardboard outer layers. A further alternative is to employ a combination of gluing and heat bonding. In this case, linear bonding lines, alternating between gluing and heat bonding lines, are arranged.
While the adhesive selected will vary according to application and use of the material, an appropriate glue or adhesive for use with the above described embodiments, and in forming a spiral wound or wound tube, is a one part cross-linking PVA or polyvinyl acetate adhesive, such as that sold under the designation DORUS KL 442.3051, which is D3 water resistant and is manufactured by Henkel.
The above described embodiments are examples only, and are not limiting in the sense of encompassing all possible variations. For example, in any of the above embodiments, or in further embodiments, two or more consecutive non-woven strength layers can be located next to each other. In the case that the two non-woven strength layers both include spaced apart filaments, tapes, ribbons, strips, chords or strands, the individual spaced filaments 110.1, 110.2, 110.3 from the two layers can partially overlap each other, as shown in
The above paragraphs describe using spiral winding preferably onto a stationary mandrel, to form the multi-layered material into tubes e.g. for concrete formwork, or a building or constructional element such as part of a pier or column, as it will remain in place. An alternative is to wrap the material around a turning mandrel for parallel wrapping.
Illustrated in
The illustration of
It will be readily understood by those in the tube winding industry, that multiple layers of the filament sheet materials 10, 100200 etc. and that depending upon the applications and hydrostatic pressures to be resisted that anything form say 2 to 25 filament layers may be required, depending upon such factors as the MPa of the concrete to be poured, the setting time thereof, the diameter and the length of the tube 1111 to be used.
For tubular formwork of lesser diameter, say 200 mm to 950 mm, as can be seen in
As is illustrated in
The tube 1111 can include at least one layer which is a hydrophobic layer such or a waterproofing layer as layer 120 from
The filaments 110.1, 110.2, 110.3, 110.4 etc. can extend in one of the following directions: in the general longitudinal direction of said multi-layered sheet material as is seen in
The filaments 110.1, 110.2, 110.3, 110.4, etc. can be one or more of the following: strips; straps; strands; tapes; the filaments are spaced from each other in said non-woven filament layer; polymeric; fibreglass; metal wire filaments; polypropylene; polyethylene; a polypropylene and polyethylene blend; polyester; or a blend of polymers.
When assembled in the tube 1111, a first non-woven filament layer such as layer 1605 has its directional strength characteristics at an angle to a second non-woven filament layer 1615.
In the above description, reference is made to filaments, and it will be readily understood that the word filament encompasses filaments of both monofilament and multifilament types.
An advantage of a non-woven filament layer in a wrapped, wound or spirally wound tube formwork or construction element, is that it leads to a reduction of cost of manufacturing, with a greater strength characteristic by comparison with a similar number of layers of prior art tubular form work such as that described in Australian patent 2004613313, wherein a tube having woven polymer mesh is described. Such reduction in cost also comes from less weight of material, as the cross woven threads of a woven polymer mesh are not present.
The advantages of the non-woven filament layer, being a combination of layers 20 and 15, or layers 25 and 20 in
Another advantage derives from the machine direction or alignment of the direction of the filament with the sheet material roll which directly creates the strength properties while the presence of cross direction woven filaments of the prior art has no functional purpose and creates a barrier to bonding. Such a woven formation creates an un-level or uneven material with elongation properties that can affect structural integrity of the formed product. Level or even filaments as described in the embodiments herein, together with bonding, creates a tube such that helical stability minimises unnecessary elongation and optimising strength together with a reduction of weight and material, by comparison to prior art systems.
The illustration of
In manufacturing spirally or other wound type tubing of various heights or lengths, and of various diameters, the numbers of layers of non-woven filament layered sheet material 10, 100, 200 etc. can be readily established by trial and error and calculation. The numbers of layers of non-woven filament layered sheet material 10, 100, 200 etc. and the finished thickness of the tubular formwork or construction element will also be dependent upon the MPa value of the concrete and its settling time. All these factors affect the hydrostatic burst pressure resistance that must be provided by the tube, as will be readily understood in the formwork and winding arts.
While the above description focuses on spiral winding, that is a helical winding, it will be readily understood that the tubular formwork or construction element can be made by straight or cylindrical winding, or other winding or wrapping techniques.
Where ever it is used, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear.
It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention.
While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2012905000 | Nov 2012 | AU | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/AU2013/001306 | 11/13/2013 | WO | 00 |
