Classifications

• • 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
  • C04B28/02—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 hydraulic cements other than calcium sulfates
  • C04B28/04—Portland cements
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
  • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
  • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
  • E04C2/2885—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material with the insulating material being completely surrounded by, or embedded in, a stone-like material, e.g. the insulating material being discontinuous
• • 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
  • 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
• • 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
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/20—Resistance against chemical, physical or biological attack
  • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
  • Y02W30/00—Technologies for solid waste management
  • Y02W30/50—Reuse, recycling or recovery technologies
  • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

• conventional concrete which is typically used for high-strength structures such as pavements and building foundations.
• Typical materials used to make conventional concrete include Portland cement, sand, crushed stone, gravel, crushed cylinders, etc.
• conventional concrete made as discussed above is not flexible or heat insulating enough to be used independently for building structure components (for example, as stand-alone insulating walls), i.e., building materials other than foundations and wall members that require secondary insulating structure.
• conventional concrete is extremely heavy limiting it yet for use as building structure components.
• the conventional concrete composition created as described above results in a rough surface having a lamination bonding quality that is erratic and inconsistent.
• laminated skin surfaces such as veneer, phenolic, vinyl, etc.
• conventional concrete is further not adequate for use as building structure components because of the inability to firmly affix laminated skin surfaces to the rough surface of the conventional concrete.
• diatomaceous earth concrete is more insulating and lightweight than conventional concrete and, therefore, is more suitable for use as some building structure components than is conventional cement.
• diatomaceous earth concrete is still not sufficiently insulating or lightweight to be used for most building structure components.
• diatomaceous earth concrete is not sufficiently light weight or flexible to be used for building structure components, especially in connection with making composite panels.
• diatomaceous earth concrete like the conventional concrete discussed above, has a rough surface to which it is difficult to firmly bond attractive, laminated skin surfaces.
• diatomaceous earth concrete will decompose at very high temperatures or upon cooling from very high temperatures.
• cellular cement is not sufficiently insulating or lightweight for use as most building structure components.
• cellular cement is not flexible and has a rough surface to which it is difficult to firmly bond laminated skin surfaces. Still further, this material will crack upon cool down from exposure to 1,800°F temperatures.
• prior art cement compositions are not suited for many building structure components or high-temperature applications. Further, due to the inflexible nature of existing cement compositions, they have proven unsuitable for use in making composite building materials that can be used as building structure components. Accordingly, it is desirable to provide a cement composition that is strong, lightweight, insulating, high-temperature resistant, flexible, and easily prepared to provide a smooth surface to which a laminated skin surface can be firmly bonded. Further, it is desirable to provide a cement composition that is particularly suited for making composite building materials. It is further desirable to provide an improved composite building material and a method for making the same.
• Premanufactured panels for building construction have in the past had a variety of constructions, the most common of which is a laminated or composite, panel.
• One such panel includes a core material of foam, or other insulating material, that may in some embodiments have vertical members for adding structural support.
• the core material is positioned between wood members and the combination fixed together, e.g., nailed, screwed, and/or glued together.
• These panels suffer from the disadvantages of being combustible as .well as inadequate sound barriers. Further, these panels are subject to rot, decay, and insect attack. Accordingly, panels constructed in this manner are not deemed satisfactory in many modern building applications.
• Still another construction for building panels provides concrete panels that are typically metal reinforced. Due to the limited compositions for concrete previously available, these panels are heavy and inflexible, making them difficult to handle and, therefore, inadequate as premanufactured building panels. These panels also suffer from the disadvantages of being expensive and poor thermal insulators. Still further, such panels also tend to "sweat" and stay damp during certain climatic conditions. For each of the foregoing reasons, prior art concrete panels have proven inadequate for many building construction applications.
• a cement composition including cement and an amount of diatomaceous earth sufficient to provide substantial heat insulation while not detracting from the strength of the cement composition.
• the cement composition used has a plurality of air pockets wherein each of the air pockets is constructed of substantially similar size and wherein the plurality of air pockets are substantially evenly distributed throughout the cement composition.
• the present invention includes an improved composite building component.
• the composite building component includes a cement composition layer having cement and a plurality of fluid pockets each being filled with a fluid.
• the cement composition layer further includes a sufficient amount of binding material to increase the flexibility of the cement composition layer.
• the composite building component also includes a layer of an insulating material positioned on one surface of the cement composition layer.
• the cement composition is used as top and bottom layers.
• the composite building component layers include cement and a plurality of fluid pockets each filled with a fluid.
• the top and bottom layers also have a sufficient amount of binding material to increase the flexibility of the layers.
• the composite building component of this embodiment has the layer of insulating material being positioned intermediate the top and bottom layers.
• a unique point of difference in this invention and common practice within the panel industry is structural and weight adjustable cement compositions are poured into preconstructed 2- to 6-sided box or half box forms in such a manner as to complete panel construction in one step, as the form box or half form box is an integral part of the final panel.
• Figure 1 is a partial isometric view of a panel constructed in accordance with the subject invention
• the above-described cement composition is superior to presently available cement compositions for use as building structure components discussed above. Further additives have been shown to further enhance the desirability of the resulting composition for use as building structure components.
• the bending strength of the composition has been significantly increased by adding to the mixture fibrous material. In addition to the fibrous material, an amount of binder chemical sufficient to hold the fibers firmly in the concrete mix was added.
• fibrous material suitable for use to increase the bendability of the resulting composition include: recycled paper fibers, wood fibers, coconut fibers, sugar cane fibers, treated glass, etc. Fibrous materials that are inert to the environment, such as, coconut, sugar cane, and recycled kraft paper fibers, are particularly preferred.
• the resulting composite structural component is highly thermally insulating (25 "R"), strong, and lightweight.
• the composite structural component may be impregnated with a polymer to provide a smooth and bondable outer surface integral with the subsurface for binding laminate finishes.
• the panels may be prepared per the above paragraph except without the insulating core placement. ' Such solid panels will not decompose upon exposure to very high temperatures (1,800°F, or greater) or upon cool down from such high temperature exposures.
• An insulating core 110 is positioned interior of the core chamber for providing insulation to the building panel 100. During construction, the insulating core 110 is mounted to the first and second support rods 106 and 108 and thereby positioned interior of the core chamber.
• the insulating core 110 may be secured to the first and second support rods 106 and 108 by a variety of methods that will readily become apparent to those skilled in the art.
• the insulating core 110 may be fabricated on the first and second support members 106 and 108 and the combination positioned in the core chamber as described above.
• the first and second support members may be placed in the core chamber and the insulating core 110 later secured thereto by suitable means.
• the first and second support rods can provide temporary support to the insulating core 110, without being secured thereto, as will be described below.
• the top 112 includes a fill hole 134 through which a filler material 134 (Figure 1) is deposited.
• the filler material is poured into the core chamber through the fill hole 134.
• the filler material fills the through connectors 132 so that when the cement composition cures, shear connectors are provided in the through connectors 132.
• the filler material 136 is selected from a material that can be introduced into the core chamber in relatively fluid form to take the form of the core chamber and to fill the through connectors 132.
• the filler material 136 is further selected to be a material that can be hardened, by curing or otherwise, to provide structural rigidity to the building panel 100.
• the filler material 136 is the improved cement composition described hereinabove.
• the building panel is prepared by placing an amount of the above-described cement composition in a mold or box form. An insulating material is then placed in the form and an additional amount of the above-described cement composition is placed on top of the insulating material so that the insulating material is intermediate the cement composition. After curing, the resulting building panel is highly thermally insulating (30+ "R"), strong, and lightweight.
• the building panel may be impregnated with a polymer to provide a smooth and bondable outer surface integral with the subsurface for binding laminate finishes.
• the inside of the first and second skin surfaces 102 and 104 are coated with an organic polymer that is dried prior to adding the filler material to the core chamber.
• first and second skin surfaces 102 and 104 illustrated in Figures 1 and 2 are placed in the box form. It will be apparent to those skilled in the art that any number and selection of surfaces of the building panel may be placed in the box form in accordance with the subject invention.
• a 4- to 6-sided box form made of magnesium oxide, or similar material is filled with a filler material with or without cores inserted.
• This configuration can be used as a fire resistant door or a building panel.
• the chief feature of this embodiment is that both main side surfaces of the 6-sided box can be customized to replicate any desired surface during the box molding process.
• This material can look like a brick, natural rock, wood, or smooth surface and it is impervious to very high heat (in excess of 2,000°F).
• organic components are added to the cement composition in addition to, or in lieu of, being added to the panel surface material.
• the panels may be prepared per the above paragraphs except without the insulating core.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Structural Engineering (AREA)
• Architecture (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Inorganic Chemistry (AREA)
• Materials Engineering (AREA)
• Organic Chemistry (AREA)
• Civil Engineering (AREA)
• Laminated Bodies (AREA)
• Building Environments (AREA)

Applications Claiming Priority (5)

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• 1993
  • 1993-03-29 JP JP5517603A patent/JPH07505356A/ja active Pending
  • 1993-03-29 WO PCT/US1993/002923 patent/WO1993020020A2/en not_active Application Discontinuation
  • 1993-03-29 EP EP19930908644 patent/EP0632793A1/de not_active Withdrawn
  • 1993-03-29 MX MX9301760A patent/MX9301760A/es unknown

Non-Patent Citations (1)

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