WO2011111032A1

WO2011111032A1 - Composition for construction elements and improved tiles

Info

Publication number: WO2011111032A1
Application number: PCT/IL2010/000200
Authority: WO
Inventors: Boaz Harpaz; Moshe Yanai; Elisha Yaakobi
Original assignee: Boaz Harpaz; Moshe Yanai; Elisha Yaakobi
Priority date: 2010-03-10
Filing date: 2010-03-10
Publication date: 2011-09-15

Abstract

A construction element comprising a cross-linkable polymer binder comprised of magnesium oxychloride cement; at least one filler; at least one phosphoric acid salt; reinforcing silica; a water-repellant; and water. From which tiles can be formed such as an improved anchoring tile that comprises a tile having a frontal face and a back side face; a support partially embedded between said frontal face and said back side face; and an anchoring member interconnected with said support wherein said anchoring member is partially embedded within said tile and partially protruded through said back side face.

Description

COMPOSITION FOR CONSTRUCTION ELEMENTS

AND IMPROVED TILES

FIELD OF THE INVENTION

The present invention relates to composition for construction elements such as to anchoring tiles. More particularly, the present invention relates to composition for construction elements that are later attached to a surface and a method of manufacturing the same. Such construction elements can be tiles comprising anchors that facilitate the attachment of the tile to another surface.

BACKGROUND OF THE INVENTION

Surfaces, such as walls, made of materials based on cement and lime can be easily destroyed by acid rain and other environmental conditions. Structural and aesthetic harms can be made to the surface, and fast wear of the materials becomes a problem. The common solution for this problem is using coatings for tiles. Today most architectural coatings and paints are comprised of binders, fillers and pigments. The main drawbacks from using the common binders that are based on a synthetic polymer are aging of the polymeric film, change in color of the film, inelasticity of the film, cracks appearing, moisture penetration etc.

Israeli Patent No. 144208 titled "Aqueous Coating Composition Useful as a Protective and Decorative Coating for Structures" by Korobov filed in 2001 discloses an aqueous coating composition, useful as a protective and decorative coating for structures, comprising: a) a cross-linkable polymer binder comprised of magnesium oxychloride cement; b) at least one filler; c) at least one phosphoric acid salt; d) reinforcing silica; e) a water- repel lant; f) water.

Such aqueous coating must be placed on the tile or surface immediately following its formation, so it will not evaporate or change. Therefore, using such aqueous coating is not suitable for coating large surfaces and areas. In addition, since the composition is solid and has high pasting capability, parts of the coating tend to be separated from the surface. Therefore, a special carrying infrastructure should be added to the surface.

Moreover, the aqueous composition if used for coating as explained in the above-mentioned patent is relatively expensive.

Since the quality of the composition described in the above-mentioned patent is high but is not useful as described therein, the inventors of the present invention invented an application in which the aqueous composition can be used to form tiles of high quality and characteristics.

Bonding of an element, such as tile or plate, to another surface is commonly used, especially in construction projects. Conventionally, tiles are set on a surface, wall for example, and are being usually bonded by a connecting material. There are several ways of bonding the tile to the surface. Examples are using plaster between the two, using an adhesive material such as a polymeric adhesion, fusing the two together, etc. Connecting materials such as described in the examples are not durable enough. With time, the material of the connector wears out and the bonding between the tile and the surface becomes loose and unstable.

In order to solve this problem, some solutions were offered. In these solutions, anchoring elements are added to the tile that helps fastening the tiles or the other construction elements to the surface. In U.S Patent No. 3,552,277 entitled "Construction Element with Helically Wound Anchor Lattice" by Avital, filed in 1968 discloses a construction element for roads or panels, comprising a slab or sheet of material, which generally is resilient, having a helical wound lattice partially embedded therein for anchoring the slab or sheet to another material. The anchor means comprises a plurality of metallic wire or rod elements each having a springlike configuration consisting of helically wound turns or coils. The coils are so arranged so that substantially the entire area of the slab to be anchored has coils arranged for anchoring it. The main disadvantage of this construction element is in the addition of plurality of metallic wires to each element that significantly increase the weight of the element. U.S Patent No. 4,522,003 entitled "Tiles and Arrangement for Setting Tiles" by Akihama et al., filed in 1983 discloses a tile with anchors that are engaged in dovetail grooves formed in the back of the tile for preventing from the mortar applied to the back of the tile coming off. Using hooks secured to the back of each tile that are secured to horizontal beams mounted on the surface to be tiled require changes both in the element and in the surface. To the element, hooks are added and to the surface, beams are added. Therefore, this solution is suitable only in surfaces that include girders that correspond to the surface or hooks of the tile.

These known in the art solutions attempt to solve the bonding problem, but create cumbersome and non efficient apparatii. There is a need for a solution that will have sufficient efficiency in facilitating the bonding of a tile to a surface.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a composition for tiles having better characteristics such as stability, strength and texture.

It is another object of the present invention to provide a tile having outstanding strength and texture.

It is another object of the present invention to provide an anchoring tile capable of facilitating the bonding of the tile to a surface.

It is another object of the present invention to provide an anchoring tile that is provided with anchors that are attached to a support embedded within the tile and facilitate the connection between the tile and the connecting material that bonds to the surface.

It is thus provided in accordance with the present invention, a construction element comprising:

a cross-linkable polymer binder comprised of magnesium oxychloride cement;

at least one filler; at least one phosphoric acid salt;

reinforcing silica;

a water-repellant;

water.

Furthermore, in accordance with another preferred embodiment, it further comprises at least one connecting element.

Furthermore, in accordance with another preferred embodiment, said at least one connecting element is undercut connecting element.

Furthermore, in accordance with another preferred embodiment, said at least one connecting element is perpendicular to the construction element.

Furthermore, in accordance with another preferred embodiment, said at least one connecting element comprises a base and a profile.

Furthermore, in accordance with another preferred embodiment, the dimensions of said profile are larger than those of said base.

Furthermore, in accordance with another preferred embodiment, said at least one connecting element are substantially parallel to each other.

Furthermore, in accordance with another preferred embodiment, further comprising aluminum stearate.

Furthermore, in accordance with another preferred embodiment, a method for forming a construction element is provided comprising:

mixing a cross-linkable polymer binder comprised of magnesium oxychloride cement, at least one filler, at least one phosphoric acid salt, reinforcing silica, a water-repellant, and water to form a composition;

placing a predetermined amount of said composition into a mold;

drying the composition within said mold to form a stable tile;

ejecting the tile from said mold. It is thus provided in accordance with another preferred embodiment, an improved anchoring tile comprising:

a tile having a frontal face and a back side face;

a support partially embedded between said frontal face and said back side face;

an anchoring member interconnected with said support wherein said anchoring member is partially embedded within said tile and partially protruded through said back side face.

Furthermore, in accordance with another preferred embodiment, said support is warp and woof wires.

Furthermore, in accordance with another preferred embodiment, said support is a grid.

Furthermore, in accordance with another preferred embodiment, said grid is extended beyond the back side face.

Furthermore, in accordance with another preferred embodiment, said support is made of a material selected of a group of materials such as metal, polymer, composite material, polymer combined with iron fibers, plastic combined with minerals, nylon, pliable metal, pliable plastic and a combination thereof.

Furthermore, in accordance with another preferred embodiment, said anchoring member is at least one spiral member.

Furthermore, in accordance with another preferred embodiment, said anchoring member is two spiral members.

Furthermore, in accordance with another preferred embodiment, said two spiral members are arranged in substantially two parallel rows.

Furthermore, in accordance with another preferred embodiment, said anchoring member is embedded within the tile in an extent of 20-30 percent of its width.

Furthermore, in accordance with another preferred embodiment, said anchoring member is interconnected with said support through a plurality of touch points between the anchoring member and the support. Furthermore, in accordance with another preferred embodiment, said anchoring member is welded to said support in said touch points.

Furthermore, in accordance with another preferred embodiment, said support is incorporated with said anchoring members.

Furthermore, in accordance with another preferred embodiment, said support is a flat plate and said anchoring members are protruded from the level of said flat plate.

Furthermore, in accordance with another preferred embodiment, said anchoring member is provided with a fastener.

It is provided in yet another preferred embodiment of the present invention, a method of constructing an improved anchoring tile comprising the following steps:

providing a tile having a void extending substantially through the area of a face of the tile;

providing at least one support in said void;

interconnecting at least one anchoring member to said at least one support;

adapting the height of said anchoring member so as to form touch points between the anchoring member and the support; filling said void with tile filling material so as to partially imbed the support within said tile and partially imbed the anchoring member within said tile.

Furthermore, in accordance with another preferred embodiment, the step of adapting the height of said anchoring member so as to form touch points between the anchoring member and the support comprises suspending said at least one anchoring member.

Additionally and in accordance with another preferred embodiment, the step of adapting the height of said anchoring member so as to form touch points between the anchoring member and the support comprises

filling a relatively thin layer of filling material;

leaving the material to partially dry;

providing at least one support in said void on said thin layer; interconnecting at least one anchoring member to said at least one support.

BRIEF DESCRIPTION OF THE FIGURES

In order to better understand the present invention and appreciate its practical applications, the following Figures are attached and references herein. Like components are denoted by like reference numerals.

Figure 1 a illustrates a construction element in accordance with a preferred embodiment of the present invention.

Figure 1 b illustrates a construction element in accordance with a preferred embodiment of the present invention.

Figure 2 illustrates a cross sectional view of a construction element comprising a connecting element in accordance with a preferred embodiment of the present invention.

Figure 3 illustrates a construction element comprising plurality of connecting elements in accordance with a preferred embodiment of the present invention. Figure 4 illustrates a construction element comprising a connecting element in accordance with a preferred embodiment of the present invention.

Figures 5a and b illustrate an isometric view of the back side of an anchoring tile in accordance with a preferred embodiment of the present invention in bare and full states respectivly. Figure 6 illustrates an isometric view of anchor in accordance with another preferred embodiment of the present invention that can be embedded in a tile. Figure 7 illustrates a cross sectional view of an anchoring tile connected to a surface in accordance with a preferred embodiment of the present invention.

Figure 8 illustrates an improved tile as shown in Figure 1 provided connected to a network in accordance with a preferred embodiment of the present invention.

Figure 9 illustrates an isometric view of an improved tile in accordance with yet another preferred embodiment of the present invention in bare state.

Figures 10 a and b illustrate two isometic views of an improved tile in accordance with yet another preferred embodiments of the present invention, in a bare and full states.

Figure 1 1 illustrates an enforced tile during construction in accordance with a preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE INEVNTION AND THE FIGURES

The present invention provides a unique and novel application for construction elements composition and a method of manufacturing the same.

The construction element of the present invention has unique characteristics of weight, strength, texture and stability that render the construction element the ability to be used to cover surfaces such as walls and floors. The composition according to the present invention can be used for variety of products and applications, such as:

A. Tiles that are used for outside cover for external walls.

B. Building boards that can replace be used instead of calcium sulfate in showers and humid areas.

C. Roofing tiles including:

C1 . A Roofing tile that is made of wood and is coated by the composition according to the present invention.

C2. A Roofing tile that is made of the composition according to the present invention.

C3. A Roofing tile that is made of a combination of the composition according to the present invention and metal coil, net or other materials.

D. Cornice molding and any other decorative molding which crowns any building or furniture element.

E. Furniture, and especially wooden pieces of furniture coated with the composition according to the present invention.

The construction element is formed from a composition of a cross- linkable polymer binder comprised of magnesium oxychloride cement binder that renders the mechanical strength to the construction element and water repellant component that imparts water resistance to the construction element. The mechanical strength of the construction element will be determined by the concentration of the magnesium oxychloride.

The composition also comprises at least one filler, phosphoric acid salt, and reinforcing silica.

The composition may also comprise aluminum stearate that is used as a water repellent agent, anti rust and hydrophobic agent.

In order to form a construction element according to the present invention, a mixture of the above mentioned components is mixed in order to form a homogeneous composition. The composition is then placed in a mold for drying period. The drying process is preferably done with no exposure to the sun light and it usually takes 48 hours. By using molds made of silicon, polyurethane or similar materials, the drying process of the composition may be reduced to be 24 hours.

The mold can be of several shapes and sizes so as to create several different construction elements and tiles.

After the composition is dried, the construction elements are ejected from the mold and are then attached to a surface such as a wall. The improved construction elements are both resistant to the abovementioned environmental conditions and are stably adhered to the surface. It should be mentioned that the construction elements can be adhered to the surface using methods that are known in the art. Moreover, the tiles can be provided with different anchoring means such as described in IL patent application number 192332 titled "Improved Anchoring Tile" filed by Harpaz et al in 2008.

Reference is now made to Figure 1 a illustrating a construction element in accordance with a preferred embodiment of the present invention. In this figure, the construction element is a Cornice. The construction element is made from the composition described herein. The composition is being molded and additional decorative moldings may crown it.

Reference is now made to Figure 1 b illustrating a construction element in accordance with a preferred embodiment of the present invention. In this figure, the construction element is a Cornice. The construction element comprises main structure 102 made of cement, wood, plastic or other material. Layer 104 is coating main structure 102 and is made of the composition described hereinbefore. Adaptor 106 is attached to main structure 102 and is capable of integrally adapting the construction element to a wall.

Reference is now made to Figure 2 illustrating a cross sectional view of a construction element comprising a connecting element in accordance with a preferred embodiment of the present invention. In this figure, the construction element is a tile 202 having an inserted undercut connecting element 204. Undercut connecting element 204 comprises a base 201 made by a cut below tile 202 so as to leave an overhang or concave profile 206. Profile 206 is used for attaching the construction element to a surface or to another element. Undercut connecting element 204 and profile 206 may be made of the same composition from which the construction element is made of or from any other material that is undercut and connected to the construction element 202 through base 201. The shape of undercut connecting material 204 is preferably designed so that the dimensions of profile 206 (marked as "a" in Figure 2) will be larger than those of base 201 (marked as "b" in Figure 2). Such shape contributes to the general stability of the construction element. The connecting element is substantially perpendicular to the construction element.

Reference is now made to Figure 3 illustrating a construction element comprising plurality of connecting elements in accordance with a preferred embodiment of the present invention. In order to stabilize the construction element and to efficiently connect it to a surface, plurality of undercut connecting elements 204 are dispersed over the surface of the construction element. By using plurality of undercut connecting elements, the construction element is easily secured to another surface. The plurality of connecting elements is substantially parallel to each other.

Reference is now made to Figure 4 illustrating a construction element comprising a connecting element in accordance with a preferred embodiment of the present invention. In this figure, the construction element is a tile 402 having an integral undercut connecting element 404. Undercut connecting element 404 is made from the same composition that the construction element is made of according to the description above. Therefore, there is no need to insert a foreign body and attaching it to the construction element.

The present invention provides an improved anchoring tile for efficiently attaching the tile to a surface. As mention herein before, the attachment of a tile to a surface wears out with time especially due to the gravitational force of the tile itself and the environmental effects. The tiles tend to separate from the connecting material and to fall down. Therefore, the present invention discloses an enforced tile that bonds having anchors that fastens the connection between the tile and the connecting material. The new and enforced tile that optionally can be made from the above mentioned composition comprises a support embedded within a portion in the backside of the tile. Anchors are provided in the backside of the tile and are protruded from the surface of the tile while interconnected with the support. When the tile is adhered to the connecting material, the anchors are dipping into the connecting material so as to enforce the connection between the tile and the connecting material to the surface

Reference is now made to Figure 5a and b illustrating an isometric view of the back side of an anchoring tile in accordance with a preferred embodiment of the present invention. Tile 500 includes two diverse faces. One face (not shown in the figure) is the front face that is displayed and therefore is refined and polished. The back face 502 of tile 500 is the face that faces the surface to which the tile is adhered. Tile 500 comprises a grid 504 that is embedded within the material that formulates the tile between both faces substantially in its entire area. Grid 504 can be arranged in different mesh size. The grid can be a commercial grid or can be made from warp and woof wires.

Back face 502 is preferably provided with two spiral members 506 that are partially embedded within the material that formulates the tile and are interconnected with grid 504. Spiral members 506 have a plurality of touch points 508 along their length with grid 504 for the purpose of enforcement between them. Optionally, the spiral members and the grid can be welded to each other in the touch points.

The spiral members are preferably arranged in two parallel rows.

The portion of the spiral members 506 that are not embedded within the tile's material substantially and homogeneously protrudes from back face 502.

Optionally, one or more spiral members are provided to the surface wherein the spiral members can be arranged in different directionalities. In any case, the spiral members are interconnected to the grid and not to each other.

The weight of the spiral members is only a small fraction (about 0.5%) from the overall weight of the tile, therefore will not render additional weight to the tile and will act only for enforcement rather than disturb the balance between the tile's weight and its connection to the surface.

As mentioned herein before, the spiral members are partially embedded within the tile material. Preferably, 20-30 percentages of the spiral members, along their length, are actually embedded within the tile. The remaining portion protrudes from the back face of the tile so as to be able to dip within the connecting material upon connection to the surface. It should be mentioned that other proportions can be implied without limiting the scope of the present invention.

It should be mentioned that the anchors can be made in any other shape other then spiral members as shown in Figure 5a.

Figure 5b illustrates frontal view of complete tile 500 after it is filled with a tile material.

Reference is now made to Figure 6 illustrating an isometric view of anchor in accordance with another preferred embodiment of the present invention that can be embedded in a tile. Anchor 600 comprises a support 602 and an anchoring means 604. Support 602 consists of two flat plates that are eventually embeded within the tile (the tile is not shown in Figure 6) that are connected by anchoring means 604. Anchoring means 604 protrudes beyond the level of the plates of support 602. When support 602 is embeded within the tile, anchoring means 604 protrudes beyond the back face of the tile similarly to the springs shown in Figure 5.

Reference is now made to Figure 7 illustrating a cross sectional view of an anchoring tile connected to a surface in accordance with a preferred embodiment of the present invention. As mentioned herein before, the tile is connected to a surface intermediated by plaster. Tile 50 comprising spiral member 506 is connected to a surface 700 that is covered by plaster 702. Spiral member 706 is dipped within plaster 702 so as to support tile 50. In order to better secure the connection fastener such as torsion spring 704 is secured to spiral member 506. Other fasteners can be used withour limiting the scope of the present invention.

An example for an effective use of a fastener is shown in Figure 8. Reference is now made to Figure 8 illustrating an improved tile 50 as shown in Figure 5 provided with a torsion spring 704 that is connected to spiral member 506. Torsion spring 704 can be used in order to fasten a connection between the improved tile and a network 706, as an example, of a surface.

It should be mention that anchoring means such as the spiral elements 506 as well as support 104 may be made of metallic wires, polymeric wires, composite materials and polymers combined with iron fibers, plastic combined with minerals, nylon, pliable metal, pliable plastic etc.

Reference is now made to Figure 9 illustrating an isometric view of an improved tile in accordance with yet another preferred embodiment of the present invention in bare state. Tile 900 is provided with support 902 that is extended beyond the surface of tile 900 to form an additional support 904.

Reference is now made to Figures 10 a and b illustrating two isometic views of an improved tile in accordance with yet another preferred embodiments of the present invention, in a bare and full states. Figure 6a illustartes a tile 1000 provided with supporting grid 1002 incorporated with the protruding anchoring means 1004. in Figure 10b the complete tile is shown wherein anchoring means 1004 protrudes beyond the back face of tile 1000 while supporting grid 1002 is embedded.

In accordance with another aspect of the present invention, it is provided a method of constructing an improved anchoring tile.

Reference is now made to Figure 1 1 illustrating an enforced tile during construction in accordance with a preferred embodiment of the present invention. A tile 50 is constructed to have a void preferably on its entire surface into which a grid 504 is to be embedded. The grid can be also partially embedded in tile 50. Grid 504 is interconnected through touch points with two spiral members 506 along the members' length. In case the touch points are not welded, two rods 1 102 are suspended on the frame of the tile. The rods are threaded through the spiral members so as to maintain the spiral members in a predetermined height so as to allow their partial embedding. When the construction is prepared as shown in Figure 1 1 , the material from which the tile is formulated is filled into the void so as to embed the grid and portion of the spiral member.

In accordance with another preferred embodiment of the present invention, the method of producing the tile comprises two stages of filling the void in the tile. In the first stage the void is partially filled with the tile material in order to fill a level of the void to accord the level of the support. After the tile material has toughened enough, support 504 and spiral members 506 are placed within the tile and the remaining tile material is poured in.

It should be mentioned that the manufacturing process can be continuous type process or batch.

It should be clear that the description of the embodiments and attached Figures set forth in this specification serves only for a better understanding of the invention, without limiting its scope as covered by the following Claims.

It should also be clear that a person skilled in the art, after reading the present specification can make adjustments or amendments to the attached Figures and above described embodiments that would still be covered by the following Claims.

Claims

C L A I M S

1. A construction element comprising:

a cross-linkable polymer binder comprised of magnesium oxychloride cement;

at least one filler;

at least one phosphoric acid salt;

reinforcing silica;

a water-repellant;

water.

A construction element as claimed in Claim 1 , further comprising at least one connecting element.

A construction element as claimed in Claim 2, wherein said at least one connecting element is undercut connecting element.

A construction element as claimed in Claim 2, wherein said at least one connecting element is perpendicular to the construction element.

A construction element as claimed in Claim 2, wherein said at least one connecting element comprises a base and a profile.

A construction element as claimed in Claim 5, wherein the dimensions of said profile are larger than those of said base.

A construction element as claimed in Claim 2, wherein said at least one connecting element are substantially parallel to each other.

8. A construction element as claimed in Claim 1 , further comprising aluminum stearate.

A method for forming a construction element comprising:

mixing a cross-linkable polymer binder comprised of magnesium oxychloride cement, at least one filler, at least one phosphoric acid salt, reinforcing silica, a water-repel lant, and water to form a composition;

placing a predetermined amount of said composition into a mold;

drying the composition within said mold to form a stable tile;

ejecting the tile from said mold.

An improved anchoring tile comprising:

a tile having a frontal face and a back side face;

a support partially embedded between said frontal face and said back side face;

1 1. The tile as claimed in Claim 10, wherein said support is warp and woof wires.

12. The tile as claimed in Claim 10, wherein said support is a grid.

13. The tile as claimed in Claim 12, wherein said grid is extended beyond the back side face.

14. The tile as claimed in Claim 10, wherein said support is made of a material selected of a group of materials such as metal, polymer, composite material, polymer combined with iron fibers, plastic combined with minerals, nylon, pliable metal, pliable plastic and a combination thereof.

15. The tile as claimed in Claim 10, wherein said anchoring member is at least one spiral member.

16. The tile as claimed in Claim 10, wherein said anchoring member is two spiral members.

17. The tile as claimed in Claim 16, wherein said two spiral members are arranged in substantially two parallel rows.

18. The tile as claimed in Claim 10, wherein said anchoring member is embedded within the tile in an extent of 20-30 percent of its width.

19. The tile as claimed in Claim 10, wherein said anchoring member is interconnected with said support through a plurality of touch points between the anchoring member and the support.

20. The tile as claimed in Claim 19, wherein said anchoring member is welded to said support in said touch points.

21. The tile as claimed in Claim 10, wherein said support is incorporated with said anchoring members.

22. The tile as claimed in Claim 21 , wherein said support is a flat plate and said anchoring members are protruded from the level of said flat plate.

23. The tile as claimed in Claim 10, wherein said anchoring member is provided with a fastener.

A method of constructing an improved anchoring tile comprising the following steps:

providing at least one support in said void;

interconnecting at least one anchoring member to said at least one support;

The method as claimed in Claim 24, wherein the step of adapting the height of said anchoring member so as to form touch points between the anchoring member and the support comprises suspending said at least one anchoring member.

26. The method as claimed in Claim 24, wherein the step of adapting the height of said anchoring member so as to form touch points between the anchoring member and the support comprises

filling a relatively thin layer of filling material;

leaving the material to partially dry;

providing at least one support in said void on said thin layer; interconnecting at least one anchoring member to said at least one support;

27. An improved anchoring tile substantially as described in the above specification, attached Figures and appending Claims. A composition for construction element substantially as described in the above specification, attached Figures and appending Claims.