US20060150554A1 - Composite for protection against wind and wind blown debris - Google Patents

Composite for protection against wind and wind blown debris Download PDF

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Publication number
US20060150554A1
US20060150554A1 US11/313,560 US31356005A US2006150554A1 US 20060150554 A1 US20060150554 A1 US 20060150554A1 US 31356005 A US31356005 A US 31356005A US 2006150554 A1 US2006150554 A1 US 2006150554A1
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US
United States
Prior art keywords
layer
composite
fibers
adhesive
wind
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Abandoned
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US11/313,560
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English (en)
Inventor
Jeffrey Hanks
Helga Kuhlmann
David Prior
Zakirhushain Dugla
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EIDP Inc
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Individual
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Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to US11/313,560 priority Critical patent/US20060150554A1/en
Priority to KR1020077018444A priority patent/KR20070100793A/ko
Priority to EP20060717946 priority patent/EP1846228A1/en
Priority to PCT/US2006/000810 priority patent/WO2006076356A1/en
Priority to MX2007008347A priority patent/MX2007008347A/es
Priority to CA 2593970 priority patent/CA2593970A1/en
Priority to JP2007551324A priority patent/JP2008526572A/ja
Priority to BRPI0606236-9A priority patent/BRPI0606236A2/pt
Assigned to E. I. DU PONT DE NEMOURS AND COMPANY reassignment E. I. DU PONT DE NEMOURS AND COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KUHLMANN, HELGA R., DUGLA, ZAKIRHUSHAIN G., HANKS, JEFFREY ALAN, PRIOR, DAVID WHITE
Publication of US20060150554A1 publication Critical patent/US20060150554A1/en
Priority to US12/151,696 priority patent/US20080222985A1/en
Abandoned legal-status Critical Current

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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H9/00—Buildings, groups of buildings or shelters adapted to withstand or provide protection against abnormal external influences, e.g. war-like action, earthquake or extreme climate
    • E04H9/14—Buildings, groups of buildings or shelters adapted to withstand or provide protection against abnormal external influences, e.g. war-like action, earthquake or extreme climate against other dangerous influences, e.g. tornadoes, floods
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/047—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/10—Next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H5/00—Armour; Armour plates
    • F41H5/02—Plate construction
    • F41H5/04—Plate construction composed of more than one layer
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H5/00—Armour; Armour plates
    • F41H5/02—Plate construction
    • F41H5/04—Plate construction composed of more than one layer
    • F41H5/0471—Layered armour containing fibre- or fabric-reinforced layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/558—Impact strength, toughness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/56—Damping, energy absorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2571/00—Protective equipment
    • 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
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A50/00—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE in human health protection, e.g. against extreme weather
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24149—Honeycomb-like
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2615—Coating or impregnation is resistant to penetration by solid implements

Definitions

  • the invention relates to the use of a high strength composite sheathing to resist penetration by wind and wind-borne debris such as that generated by severe storm events, particularly tornadoes.
  • Storm shelters and cellars are necessary to provide a safe haven for protection against severe storm events in regions prone to tornado or hurricane activity. These shelters have been typically constructed of poured concrete, steel reinforced masonry, or heavy weight sheet metal. Details of adequate designs for storm shelters and cellars are detailed in publications from the Federal Emergency Management Agency (FEMA) such as Taking Shelter from the Storm—Publication 320 and Design and Construction Guidance for Community Shelters—Publication 361. The current designs rely on the use of common heavyweight construction materials such as concrete and steel to provide the resistance to wind-borne debris generated in the storm event.
  • FEMA Federal Emergency Management Agency
  • U.S. 2003-0079430 A1 published May 1, 2003 discloses a fiber reinforced composite sheathing employing a fabric of high strength fibers bonded with resin in combination with structural sheathing.
  • the composite has an ability to withstand a 15-pound projectile at a speed of 161 kilometers (100 miles) per hour.
  • U.S. patent application Ser. No. 10/308,492 sets forth the composite of U.S. 2003-0079430 A1 in combination with a layer of material having a density not greater than 0.25 grams per cubic centimeter.
  • wind speeds generated by tornadoes can exceed 200 miles per hour which is greatly in excess of wind speeds generated by hurricanes. Therefore, a particular need exists for the lightweight field workable sheathing to withstand both wind and wind-borne debris generated by the higher tornado wind speeds.
  • the present invention is directed to:
  • the adhesively bonded composite can be designed to meet both the wind pressure and windborne debris requirements by selection of the core and structural sheathing properties, so as to meet the specifications listed above, and in accordance with available structural design formula for foam filled structures. These formulas can be found in publications such as “Design of Foam-Filled Structures,” by John Hartsock, and “Design and Fabrication of Plywood Sandwich Panels” published by the American Plywood Association.
  • the composite is particularly adapted for construction of storm shelters and residences located in areas of the world which are subjected to wind-blown debris not only by hurricanes but also from the substantially higher wind speeds of tornadoes.
  • FIG. 1 represents a load deflection curve for an 86-inch long panel of Examples 1, 2 and 3 in accordance with ASTM E72 Traverse Load Test.
  • the present invention is an improvement in formation of a composite employing a high strength bonded fabric layer as defined in the Summary of the Invention.
  • the high strength bonding fabric layer in combination with structural sheathing is highly effective in providing protection against wind blown debris, a need is present for protection against the force of only wind in a free standing composite.
  • the present invention overcomes a need for a robust and/or complicated framing structure to hold a composite in place. Due to rigidity yet as the same time flexibility in the composite, protection is obtained from the effects of wind per se and wind blown debris.
  • Rigidity in the composite is necessary to obtain protection opposite air pressure generated due to wind speed. Flexibility is present in the composite opposite wind blown debris wherein debris can puncture an outer sheathing before striking a high strength bonded fabric which will deflect in a range of 5.0 to 17.5 centimeters when impacted by a 6.8 kilogram (15 pound) projectile at a speed of 161 kilometers (100 miles) per hour in accordance with ASTM test procedure E1886-97.
  • a necessary component for protection against wind-blown debris such as generated by tornadoes with wind speeds in excess of 200 miles per hour is a fabric containing high strength fiber.
  • the fabric may be a woven or non-woven although a woven fabric is preferred.
  • High strength fibers are well known and as employed herein means fibers having a tenacity of at least 10 grams per dtex and a tensile modulus of at least 150 grams per dtex.
  • Yarns can be made from fibers such as aramids, polyolefins, polybenzoxazole, polybenzothiazole, glass and the like, and may be made from mixtures of such yarns.
  • the fabric may include up to 100 percent aramid fiber.
  • aramid is meant a polyamide wherein at least 85% of the amide (—CO—NH—) linkages are attached directly to two aromatic rings. Examples of aramid fibers are described in Man-Made Fibers-Science and Technology 1 Volume 2, Section titled Fiber-Forming Aromatic Polyamides, page 297, W. Black et al., Interscience Publishers, 1968. Aramid fibers are, also, disclosed in U.S. Pat. Nos. 4,172,938; 3,869,429; 3,819,587; 3,673,143; 3,354,127; and 3,094,511.
  • Para-aramids are common polymers in aramid yarn and poly(p-phenylene terephthalamide) (PPD-T) is a common para-aramid.
  • PPD-T poly(p-phenylene terephthalamide)
  • PPD-T is meant the homopolymer resulting from mole-for-mole polymerization of p-phenylene diamine and terephthaloyl chloride and, also, copolymers resulting from incorporation of small amounts of other diamines with the p-phenylene diamine and of small amounts of other diacid chlorides with the terephthaloyl chloride.
  • PPD-T means copolymers resulting from incorporation of other aromatic diamines and other aromatic diacid chlorides such as, for example, 2,6-naphthaloylchloride or chloro- or dichloroterephthaloyl chloride or 3,4 -diaminodiphenylether.
  • polyolefin polyethylene or polypropylene.
  • polyethylene is meant a predominantly linear polyethylene material of preferably more than one million molecular weight that may contain minor amounts of chain branching or co-monomers not exceeding 5 modifying units per 100 main chain carbon atoms, and that may also contain admixed therewith not more than about 50 weight percent of one or more polymeric additives such as alkene-1-polymers, in particular low density polyethylene, propylene, and the like, or low molecular weight additives such as anti-oxidants, lubricants, ultra-violet screening agents, colorants and the like which are commonly incorporated. Such is commonly known as extended chain polyethylene (ECPE).
  • polypropylene is a predominantly linear polypropylene material of preferably more than one million molecular weight. High molecular weight linear polyolefin fibers are commercially available.
  • Polybenzoxazole and polybenzothiazole are preferably made up of polymers of the following structures:
  • While the aromatic group shown joined to the nitrogen atoms may be heterocyclic, they are preferably carbocyclic; and while they may be fused or unfused polycyclic systems, they are preferably single six-membered rings. While the group shown in the main chain of the bis-azoles is the preferred para-phenylene group, that group may be replaced by any divalent organic group which does not interfere with preparation of the polymer, or no group at all. For example, that group may be aliphatic up to twelve carbon atoms, tolylene, biphenylen, bis-phenylene either, and the like.
  • a further requirement in the present invention is the use of a resin to bind individual fibers of the high strength fibers in the employed fabric.
  • the resin may be selected from a wide variety of components such as polyethylene, ionomers, polypropylene, nylon, polyester, vinyl ester, epoxy and phenolics and thermoplastic elastomers.
  • the resin may be applied to the fabric containing high strength fibers by coating or impregnation, such as under pressure.
  • the high strength fabric/resin combination must have an ability for deflection within the layered composite when tested in accordance with National Performance Criteria for Tornado Shelters, First Addition, FEMA, May 28, 1999 using ASTM Test Method E1886-97, entitled “Standard Test Method for Performance of Exterior Window, Certain Walls, Doors and Storm Shutters Impacted by Missile(s) and Exposed to Cyclic Pressure Differentials.” Highlights of the test include mounting the test specimen, impacting the specimen with a 6.8 kilogram (15 pound) 2 ⁇ 4 missile propelled-at a speed of 161 kilometers (100 miles) per hour and observing and measuring the test results.
  • the ASTM test procedure E1886-97 is specific to the various requirements such as the use of 2 ⁇ 4 lumber missile, missile propulsion device, speed measuring system and use of a high-speed video or photographic camera. It is understood, herein, that the test procedure for purposes of the present disclosure, involves attaching any test specimen to a suitable support frame, in such a way that is representative of an actual wall installation. Such specimen is then impacted on the plywood face at or near the center of the panel.
  • the 2 ⁇ 4 lumber missile should be marked with suitable indexing marks to allow the tracking of the depth of penetration of the projectile.
  • the photographic or video camera should be positioned to monitor the depth of penetration of the projectile and such camera should have a minimum frame rate of 1000 frames per second.
  • the fabric containing high strength fibers bonded with a resin will deflect within a range from 5.0 to 17.5 cm. More preferably, the deflection will be in a range from 8.0 to 16.0 cm and most preferably 10.0 to 15.0 cm. It is understood the deflection of the fabric would be typically performed in a separate test procedure on a sheathing (such as plywood)/fabric combination which is not bonded to one another. In such case the sheathing/fabric separate from one another in the test procedure.
  • a sheathing such as plywood
  • the degree of deflection may be determined by its final use in a building structure.
  • a maximum stated deflection of the fabric/resin combination may be undesirable in a residence due to the proximity of an occupant adjacent a wall containing the cloth/resin combination.
  • a minimum deflection within the above range can require an added thickness of the fabric resulting in a high cost of construction.
  • fabric is inclusive of more than one layer of a cloth.
  • deflection means the maximum measured distance of separation of the high strength fabric/resin combination from the structural sheathing (i.e. the separation due to the impact). As previously stated the test procedure is undertaken when the high strength fabric/resin combination is not bonded to the sheathing.
  • the measurement must be undertaken in conjunction with high-speed photography.
  • deflection measurement if during the test procedure with the projectile, there may be some bowing of the structural sheathing.
  • the measurement for deflection is the distance, i.e., the separation, of the high strength fabric/resin combination from the bowed portion of the sheathing. It can be determined from review of the photographic or video record collected during previously described testing, determining the maximum depth of penetration during the event, and subtracting the thickness of the structural sheathing.
  • the combination of the fabric containing the high strength fibers/resin is for employment with a wood based or other structural sheathing material, since an additional purpose of the combination is the structural reinforcement of a wall or door.
  • structural sheathing is inclusive of any material which provides structural building support. The preferred material is wood, particularly plywood, due to extensive use in the building industry. However other materials are known for structural sheathing serving as building support: a typical example is fiberboard reinforced with cement.
  • the fabric/resin combination is generally flexible and will be employed with the sheathing which for purposes of illustration may be at least 0.65 cm (one quarter inch) and preferably for purposes of support, at least 1.27 cm (one half inch). The type of structural sheathing is not critical to the success of the present invention.
  • the sheathing may be solid such as from hard or soft woods or may be in the form of a composite such as plywood or a non-wood sheathing such as cementous fiberboard plastic composite and thin gauge metal.
  • a composite such as plywood or a non-wood sheathing such as cementous fiberboard plastic composite and thin gauge metal.
  • There is no maximum thickness to the structural sheathing which in a building structure will be or face an outer wall with the combination of fabric/resin facing the inner portion of the building, i.e., for example a room where inhabitants are to be protected.
  • structural sheathing will be present on opposite faces of the composite holding the remaining components in a sandwich construction. It is understood that the layers of structural sheathing need not be identified.
  • the structural sheathing face the direction of any wind-borne debris such that the debris strikes the sheathing with penetration before contact and containment with deflection of the combination of cloth/resin. It is understood that the invention is particularly advantageous since conventional building construction and techniques with structural sheathing may be employed.
  • the lightweight material will have a density of not greater than 0.25 grams per cubic centimeter, preferably, not greater than 0.10 grams per cubic centimeter, and more preferably, not greater than 0.05 grams per cubic centimeter.
  • the lightweight material may be flexible or rigid. However, it is within the scope of the present invention for rigidity to be provided by support or reinforcement of the lightweight material. Therefore, the lightweight material may not be self-supporting but the overall lightweight material layer will have flexibility or rigid through use of a support or reinforcement to provide this property. Therefore, in a preferred mode, the layer containing the lightweight material is self-supporting, i.e., it will not collapse. In this preferred mode, sufficient shear modulus and shear strength is needed in the lightweight material to provide for the wind pressure resistance. The needed shear stiffness and strength can be calculated from common design formula using the previous detailed references, depending on the make-up of the structural skins, thickness of the lightweight core, and length of the composite panel being produced.
  • the lightweight materials include, for example, polystyrene and polyurethane, which can be present as foams or honeycomb structures made, for example, from kraft paper, aramid paper, aluminum sheeting and plastic.
  • the lightweight material will typically need a shear modulus greater than 300-pounds/square inch and a shear strength greater than 25-pounds/square inch to provide resistance to 250 mile per hour winds. These properties are typically present in expanded polystyrene foam with a density greater than 1.0 pound/cubic foot.
  • the lightweight material can as well be a foam structure reinforced with light-gauge steel members or wires as described in U.S. Pat. No. 4,241,555. However, such use is not necessary due to use of an adhesive on opposite sides of the lightweight material.
  • the thickness of the lightweight material layer is not critical with an example in the range of 5.0 to 20.0 centimeters.
  • the shear strength and shear modulus must be higher to provide for the wind resistance.
  • the shear modulus and shear strength can be lower.
  • three layers of adhesive are employed, namely (a) between structural sheathing, and material having a density not greater than 0.25 grams per cubic centimeter), (b) between the material having a density not greater than 0.25 grams per cubic centimeter and fabric containing high strength fibers bonded with a resin and, (c) fabric containing high strength fibers bonded with a resin and structural sheathing.
  • the types of adhesive are not considered critical and can be the same resins as described for bonding the high strength fibers, but adhesives must provide sufficient bond strength to make the composite act as a single unit resisting bending under the pressure created by the impinging wind.
  • a 48-in by 86-in laminated wall panel was produced in a pneumatic platen press by stacking in sequence the following materials:
  • the glue was applied as detailed above with an industrial glue roll coater.
  • the assembled panel was placed in the pneumatic press and held under pressure of 7-lbs/sq-in for one hour and the glues allowed to fully cure over 24 hours, before being sent for testing.
  • the panel was pressure tested in a vacuum rig in accordance with ASTM test method E72.
  • the panel failed at a pressure of 425 lbs/sq-ft and showed excessive deformation and a non-linear load deflection cure.
  • the load deflection curve is shown in the Figure.
  • the ultimate failure load of this panel would not provide the margin of safety needed for use in the highly loaded sections of wind shelters, and would not provide the needed rigidity in the walls to meet typical building standards for load bearing walls.
  • An additional 48-in-by-48-in test panel was produced as described above to access the ability of the wall to resist the penetration by windborne debris.
  • the panel was impact tested, with a 15-pound lumber projectile at a speed of 161 kilometers (100 miles) per hour in accordance with ASTM test procedure E1886-87. The projectile did not penetrate the wall.
  • a 48-in by 86-in laminated wall panel was produced in a pneumatic platen press as described in Example 1 with 4-inch thick expanded polystyrene foam core with the density increased to 2.5 lb/cu-ft.
  • the panel was pressure tested in a vacuum rig in accordance with ASTM test method E72.
  • the panel failed at a pressure of 673 lbs/sq-ft and showed low deformation and a linear load deflection cure.
  • the load deflection curve is shown in the Figure.
  • the ultimate failure load of this panel would provide the margin of safety needed for use in the highly loaded sections of wind shelters, and would provide the needed rigidity in the walls to meet typical building standards for load bearing walls.
  • An additional 48-in-by-48-in test panel was produced as described above to access the ability of the wall to resist the penetration by windborne debris.
  • the panel was impact tested, with a 15-pound lumber projectile at a speed of 161 kilometers (100 miles) per hour in accordance with ASTM test procedure E1886-87. The projectile did not penetrate the wall.
  • a 48-in by 86-in laminated wall panel was produced in a pneumatic platen press as described in Example 1 with 4-inch thick expanded polystyrene foam core with the density increased to 3.0 lb/cu-ft.
  • the panel was pressure tested in a vacuum rig in accordance with ASTM test method E72.
  • the panel failed at a pressure of 673 lbs/sq-ft and showed low deformation and a linear load deflection cure.
  • the load deflection curve is shown in the Figure.
  • the ultimate failure load of this panel would provide the margin of safety needed for use in the highly loaded sections of wind shelters, and would provide the needed rigidity in the walls to meet typical building standards for load bearing walls.
  • An additional 48-in-by-48-in test panel was produced as described above to access the ability of the wall to resist the penetration by windborne debris.
  • the panel was impact tested, with a 15-pound lumber projectile at a speed of 161 kilometers (100 miles) per hour in accordance with ASTM test procedure E1886-87. The projectile did not penetrate the wall.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Wood Science & Technology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Business, Economics & Management (AREA)
  • Emergency Management (AREA)
  • Environmental & Geological Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Laminated Bodies (AREA)
  • Building Environments (AREA)
  • Buildings Adapted To Withstand Abnormal External Influences (AREA)
  • Panels For Use In Building Construction (AREA)
US11/313,560 2005-01-13 2005-12-21 Composite for protection against wind and wind blown debris Abandoned US20060150554A1 (en)

Priority Applications (9)

Application Number Priority Date Filing Date Title
US11/313,560 US20060150554A1 (en) 2005-01-13 2005-12-21 Composite for protection against wind and wind blown debris
CA 2593970 CA2593970A1 (en) 2005-01-13 2006-01-10 Composite for protection against wind and wind blown debris
EP20060717946 EP1846228A1 (en) 2005-01-13 2006-01-10 Composite for protection against wind and wind blown debris
PCT/US2006/000810 WO2006076356A1 (en) 2005-01-13 2006-01-10 Composite for protection against wind and wind blown debris
MX2007008347A MX2007008347A (es) 2005-01-13 2006-01-10 Compuesto para proteccion contra el viento y escombros arrastrados por el viento.
KR1020077018444A KR20070100793A (ko) 2005-01-13 2006-01-10 바람 및 바람에 날리는 파쇄물에 대한 보호용 복합재
JP2007551324A JP2008526572A (ja) 2005-01-13 2006-01-10 風および風に吹き飛ばされる破片からの保護のための複合体
BRPI0606236-9A BRPI0606236A2 (pt) 2005-01-13 2006-01-10 compósito e estrutura de construção
US12/151,696 US20080222985A1 (en) 2005-01-13 2008-05-08 Composite for protection against wind and wind blown debris

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US64351905P 2005-01-13 2005-01-13
US11/313,560 US20060150554A1 (en) 2005-01-13 2005-12-21 Composite for protection against wind and wind blown debris

Related Child Applications (1)

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US12/151,696 Continuation US20080222985A1 (en) 2005-01-13 2008-05-08 Composite for protection against wind and wind blown debris

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US20060150554A1 true US20060150554A1 (en) 2006-07-13

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US11/313,560 Abandoned US20060150554A1 (en) 2005-01-13 2005-12-21 Composite for protection against wind and wind blown debris
US12/151,696 Abandoned US20080222985A1 (en) 2005-01-13 2008-05-08 Composite for protection against wind and wind blown debris

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US12/151,696 Abandoned US20080222985A1 (en) 2005-01-13 2008-05-08 Composite for protection against wind and wind blown debris

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US (2) US20060150554A1 (enExample)
EP (1) EP1846228A1 (enExample)
JP (1) JP2008526572A (enExample)
KR (1) KR20070100793A (enExample)
BR (1) BRPI0606236A2 (enExample)
CA (1) CA2593970A1 (enExample)
MX (1) MX2007008347A (enExample)
WO (1) WO2006076356A1 (enExample)

Cited By (6)

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US20080176051A1 (en) * 2007-01-24 2008-07-24 Nguyen Huy X Hurricane resistant composites
US20090061714A1 (en) * 2007-08-27 2009-03-05 Nguyen Huy X Hurricane resistant composites
US20110005695A1 (en) * 2008-03-03 2011-01-13 Nicholas Boone Transportable Modular System Permitting Isolation of Assets
US8039102B1 (en) 2007-01-16 2011-10-18 Berry Plastics Corporation Reinforced film for blast resistance protection
US9790406B2 (en) 2011-10-17 2017-10-17 Berry Plastics Corporation Impact-resistant film
US20220098860A1 (en) * 2019-01-11 2022-03-31 Plants Laboratory, Inc. Heat-shielding panel and prefabricated building

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Publication number Priority date Publication date Assignee Title
JP6187559B2 (ja) * 2015-09-11 2017-08-30 東レ株式会社 構造物およびその製造方法
US11008757B1 (en) 2020-04-01 2021-05-18 Decker Hall Innovations, LLC Method for securing multiple layers of roofing materials

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* Cited by examiner, † Cited by third party
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US8039102B1 (en) 2007-01-16 2011-10-18 Berry Plastics Corporation Reinforced film for blast resistance protection
US20080176051A1 (en) * 2007-01-24 2008-07-24 Nguyen Huy X Hurricane resistant composites
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US9790406B2 (en) 2011-10-17 2017-10-17 Berry Plastics Corporation Impact-resistant film
US20220098860A1 (en) * 2019-01-11 2022-03-31 Plants Laboratory, Inc. Heat-shielding panel and prefabricated building

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CA2593970A1 (en) 2006-07-20
BRPI0606236A2 (pt) 2009-06-09
MX2007008347A (es) 2007-08-03
US20080222985A1 (en) 2008-09-18
JP2008526572A (ja) 2008-07-24
EP1846228A1 (en) 2007-10-24
WO2006076356A1 (en) 2006-07-20
KR20070100793A (ko) 2007-10-11

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