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

• the present invention is directed toward improved cement compositions and building materials therefor and, more particularly, the present invention is directed toward an improved cement composition with improved properties and a construction for premanufactured, composite panels using the improved cement composition, which improved composite panels exhibit improved strength, weight, and size characteristics.
• 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.
• Additional structural criteria that may effect the structural specifications are fire resistance, thermal efficiency, acoustical rating, rot and insect resistance, and water resistance.
• premanufactured panels it is desirable for premanufactured panels to be readily transportable, e.g., lightweight, easily packaged, and easily handled.
• 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.
• a foam core is positioned between metal members.
• Decorative material is typically bonded to the outside of the metal members to provide these building panels.
• These panels are expensive and suffer from the disadvantage of being very sound transmissive. As a result of their sound transmission properties, an inside wall is generally required to provide an acoustical barrier, thereby further increasing the cost of using these panels. Such panels are not generally suitable for load-bearing 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 building panel that is lightweight and strong. It is further desirable to provide such a building panel that is also a good heat and sound insulator. It is further desirable to provide such a building panel that is also resistant to water, fire and rotting. It is also desirable to provide a building panel having all of the foregoing properties, and which is easily handled.
• 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.
• a method for making structural cement includes the step of impregnating the surface of the structural cement with a material which converts the surface and subsurface of the structural cement to both strengthen the bondability of the surface and provide a smooth surface.
• 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.
• solid panels ranging from 1" to 4" thickness are poured. These panels can be used with or without laminated skin surfaces in applications where the material is exposed, or may be exposed, to very high temperatures in the range of 1,800 degrees F, or greater. In these applications the panels will resist such high temperatures and cool down from such high temperatures without decomposition.
• the present invention also provides a method for constructing building panels including the step of applying an organic component to a panel surface material and permitting the organic polymer to dry.
• a filler material is provided wherein the filler material includes a sufficient amount of an organic compound to bond with the organic component on the surface of the panel surface material.
• the panel surface material is then positioned in contact with the filler material while the filler material is being poured/placed so that the organic polymer of the panel surface material will bond with the organic polymer of the filler material in order that the panel surface material will become a bound integral part of the building panel.
• 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.
• the filler material of building panels constructed in accordance with the method of the subject invention is a cement composition containing fluid pockets wherein each of the fluid pockets is of substantially similar size and wherein the fluid pockets are substantially evenly distributed throughout the cement base.
• the building panel may also include panel surface material having an organic component applied to a first side thereof wherein the first side of the panel surface material is substantially integrally formed with the cement base by the bonding of organic components.
• Figure 1 is a partial isometric view of a panel constructed in accordance with the subject invention
• Figure 2 is a partial exploded view of the panel illustrated in Figure 1;
• Figure 3 is a partial isometric view of the panel illustrated in Figures l and 2.
• an improved cement composition is provided for use in making building structure components.
• the cement composition disclosed herein is lightweight, strong, flexible, and insulating enough for use as wall panels, roofs, subfloors, planks, ceiling panels, building bricks, refractory brick, fire core, shingles, and most other building structure components.
• the cement composition that is the subject of the present invention is made in manner so that its surface is substantially smooth. Accordingly, laminated skin surfaces are readily bonded to the surface of the cement composition of the subject invention.
• the improved cement composition is created from cellular cement and a sufficient amount of diatomaceous earth to substantially improve the insulating and fire-resistance properties of the composition while not detracting materially from its strength.
• the cellular cement is created to include a plurality of fluid pockets having substantially the same size and shape, wherein the fluid in the pockets is of a density less than that of the cement used in the composition.
• the cellular cement has about a 200 pound per square inch strength, obtained by including approximately 4,100 pockets per cubic inch, wherein each pocket is approximately 0.06-0.08 inch, in a cement and diatomaceous earth composition resulting in a cement composition having a density of about 10-35 pounds per cubic feet.
• the density of the cement composition can be increased or decreased by decreasing or increasing, respectively, the density of the fluid pockets.
• the cement composition as described above has been found to provide the best insulating properties and consistent strength when the plurality of fluid pockets are of uniform size and shape and are evenly distributed through the cement composition. Although several methods can be used to cellularize cement, bubbles of uniform size and shape that are uniformly distributed are difficult to obtain by most methods.
• One presently preferred method is to mix the cement composition with a chemical mixture that reacts with the cement composition to provide small bubbles of uniform size and shape that are spread uniformly throughout the composition.
• One presently preferred chemical mixture is a proprietary product that is commercially available from Celcore, Inc., located in North Royalton, Ohio (referred to herein as "the Celcore component").
• the cellular nature of the cement composition of the present invention increases the insulating and fire-resistance properties of the cement while decreasing its weight.
• the addition of diatomaceous earth further increases the insulating and fire-resistance properties of the cement composition without significantly decreasing the strength of the composition.
• Optimum characteristics have been obtained using about 3%-15% diatomaceous earth in the cement composition, as will be discussed in more detail below by reference to the several examples.
• the addition of the diatomaceous earth increases the insulating properties of the composition by a factor of 1.5 to 9 over prior art compositions of similar weight and strength.
• the cement composition is able to withstand extremely high temperatures for extended periods of time and not crack upon cool down.
• cement compositions made in accordance with the above-described method have withstood l,800d°F temperatures for at least 2 hours without decomposition, and not cracked upon cool down.
• 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.
• fiber and diatomaceous earth provides wood qualities to the resulting composition to enable the material to be worked in a manner similar to wood, t.e., nailed, sawed, drilled, routed, etc.
• Wood fiber can be adequately added to the material using paper fiber.
• approximately l%-20% of wood fiber is added to the composition to provide suitable wood qualities.
• an amount of polymer may be added to the cement composition to increase its flexibility.
• a polymer can be added to react with the Portland cement to increase the elasticity of the particles of the cement composition.
• a polymer can be added which is selected to be non- reactive with the Portland cement particles to increase the elasticity intermediate the particles of the cement.
• a non-PVA polymer can be used to react with the cement and a PVA polymer can be used to be non-reactive with the cement particles.
• silica is another additive found to enhance the strength of the subject cement composition and, accordingly, its suitability for use as the building structure components described above. The addition of silica increases the strength of the resulting composition.
• silica fume is used to uniformly add silica to the cement composition.
• silica can be added to the cement composition in a number of manners. In a presently preferred embodiment of the invention, approximately 3%-10% silica is added to the composition, in a form suitable for cement hardening.
• the above- described cement compositions are treated after curing to provide a smooth surface suitable for being firmly bonded to laminated skin surfaces, such as veneer, phenolic, vinyl, treated papers, etc.
• the cured cement composition is impregnating with specialized polymers to a depth selected to provide a sufficiently smooth top surface and subsurface integration to the top surface to provide maximum strength for bonding to laminated skin surfaces. Impregnation may be accomplished by any of several methods known in the art for impregnating materials to predetermined depths.
• the impregnation may be accomplished by dipping or spraying at room or elevated temperatures, at atmospheric or elevated pressures and curing by RF exposure, high temperature or long-term curing methods.
• the cured composition is impregnated with a specialized polymer to a depth of approximately 1/4 to 1 inch.
• the cement compositions described above are particularly suited for building structure components such as wall panels, roofs, subfloors, planks, ceiling panels, bricks, and most other building structure components.
• One presently preferred use of the cement compositions described above is for making structural panels adequate to meet, or exceed, most governmental building code regulations for strength and thermal insulation.
• the structural panels made with the cement compositions described above is lightweight making use of the materials easier thereby decreasing the cost of the resulting structure.
• the building structure components of the subject invention are made 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.
• 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.
• the panels may be prepared, without the insulating core, using a higher density cement composition and cut into building bricks.
• Such bricks have been made with density ranging from 30 to 100 pounds per cubic foot with strengths up to 1,200 PSI.
• a building panel 100 constructed in accordance with the subject invention is illustrated in Figures 1, 2, and 3.
• the building panel 100 includes first and second skin surfaces 102 and 104 positioned on opposite sides of the panel 100.
• the skin surfaces 102 and 104 are separated by a top and bottom 112 and 114, respectively, and first and second joining sides 116 and 118.
• the first and second skin surfaces 102 and 104, the top and bottom 112 and 114, and the first and second joining sides 116 and 118, are fastened together to form a core chamber, as will be described in more detail below.
• the first and second joining sides 116 and 118 each have a tongue and groove 120 formed therein.
• the tongue and groove 120 extends from the top 112 to the bottom 114.
• the first joining side 116 is positioned with its tongue extending toward the second joining side 118 and the second joining side is positioned with its tongue extending away from the first joining side 116 so that the tongue and groove of adjacent building panels will mate with one another.
• the tongue and grooves 120 are therefore used for connecting a plurality of building panels 100 to construct a structure as is known in the art.
• the building panel 100 also includes a handling system having first and second support rods 106 and 108 that extend from the top 112 to the bottom 114.
• the support members may be constructed of metal, plastic, or other material suitable for supporting the insulating core during preparation of the building panel.
• the first and second support rods each have an engagement system including a plurality of female/female connectors 126 fixed to first and second threaded ends 122 and 124 of the first and second support rods 106 and 108.
• the handling system including the first and second support rods 106 and 108, is an integral part of the building panel 100.
• the handling system provides support to the building panel 100 when it is being constructed and, in combination with the engagement system, facilitates handling of the building panel 100 after it is constructed.
• any connector of proper size having male threads can be mated with the female/female connectors of the building panel 100 to enable handling of the building panel.
• an eyelet 128 ( Figure 3) may be mated with the female/female connectors 126 to enable lifting and positioning of the building panel 100 with construction machinery.
• a bolt 130 may be mated with the female/female connectors 126 to fix a roof structure or other structure to the building panel 100.
• 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 is positioned substantially centered between the first and second skin surfaces 102 and 104, the top and bottom 112 and 114, and the first and second joining sides 116 and 118.
• 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 insulating core 110 may be selected for providing any type of insulation to the building panel 100.
• the insulating core 110 may be selected to provide thermal, noise, or other insulation to the building panel 100.
• a lightweight material is selected for the insulating core 110 so that the strength to weight ratio of the building panel 100 can be maximized.
• the insulating core 110 also includes a plurality of through connectors 132 that extend from the first side 102 to the second side 104 to provide shear connectors to the panel 100, as will be described in more detail 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 filler material 136 is selected to provide predetermined load bearing strength and weight characteristics. In applications where the load bearing strength can be less than that desired for building panels, materials much lighter than the cement composition discussed above may be used for the filler material 136. After the filler material 136 is introduced into the core chamber to take the form of the core chamber, and to fill the through connectors 132 the filler material is cured or dried, by the most appropriate method.
• the resulting panel will include a plurality of shear connectors that are formed by the fill material in the through-holes 132.
• the effect of the shear connectors is to substantially increase the shear strength of the building panel 100.
• the shear strength of the building panel can be increased and/or decreased by varying the number and positioning of shear connectors, i.e., varying the number and positioning of through-holes in the insulating core 110.
• the construction for the building panel 100 provides the user with the ability to select load bearing strength, shear strength, and weight, by varying the composition of the filler material and the construction and positioning of the shear connectors.
• both the load bearing strength and the shear strength of the building panel 100 may be altered by varying the size and positioning of the insulating core 110.
• the resulting building panel may be constructed with compressive strengths in excess of about 40,000 pounds per square inch (per ASTM E-72 which calls for worst case eccentric loading) and weight of 3 to 10 pounds per square foot (based on 4' x 8' x 6" panel). Further, the building panel is fire and water proof and impervious to rot and insect damage. Still further, the building panel is a good thermal and acoustical insulator. A typical building panel, constructed with a thickness of 6 inches will exhibit an insulating value in excess of R30. Structural panels made with the cement compositions described above are lightweight, so that it is easier to handle the structural panels, thereby decreasing the cost of the resulting structure. A particular preparation for the composite structural component is a building panel.
• 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.
• the organic polymer is applied while the first and second skin surfaces 102 and 104 are positioned inside the core chamber, however, those skilled in the art will appreciate that the organic polymer may be added to the first and second skin surfaces 102 and 104 prior to positioning them in the core chamber.
• the organic polymer is typically selected to provide bonding strength between the first and second skin surfaces 102 and 104 and the filler material 136 when the filler material contains compatible bonding agents that react with the coated surfaces of the first and second skin surfaces. Suitable organic polymers for application to the first and second skin surfaces will readily become apparent to those skilled in the art.
• a box form is provided with an outside dimension corresponding to the width, height, and thickness of the desired building panel.
• the box form includes first and second generally planar sides that are spaced from one another by a distance corresponding to the desired thickness of the building panel.
• Support members such as first and second support rods 106 and 108 ( Figures 1 and 2), are positioned interior of the box form for supporting an insulating core during preparation.
• the support members are generally oriented horizontally and/or vertically and positioned centrally of the box form.
• An insulating core is then positioned proximate the support members thereby to be supported in the box form generally centered between the first and second planar sides.
• a panel surface material such as for example, a laminate or other known skin surface, is positioned inside the box form proximate the first and second planar sides.
• the panel surface material may comprise one or more sides of the resulting building panel.
• all six surfaces of the building panel are placed in the box form, e.g., first and second skin surfaces 102 and 104, top and bottom 112 and 114, and first and second joining sides 116 and 118, described by reference to Figures 1 and 2, may be placed in the box form.
• 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.
• 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. Still further, the panels may be prepared, without the insulating core, using a higher density cement composition and cut into building bricks. Such bricks have been made with density ranging from 30 to 100 pounds per cubic foot with compressive strengths up to 1,200 PSI.
• Approximately 4% diatomaceous earth was added to Portland cement and the composition mixed as is standard in the art. After mixing, a 5 chemical component provided by the Celcore company, Le., the Celcore component referenced above, was added to the mixture to provide a cement composition having approximately 4,100 air pockets per cubic inch, a density of 25 pounds per cubic foot, strength of about 200 PSI, and thermal insulation value of approximately 3 "R" per inch.
• the resultant product can be heated to 1,800°F and 10 uniquely, then, can be cooled to ambient temperature without cracking or decomposer.
• Example No. 5 The material produced as in Example No. 5, above, was used to construct a 6" thick composite panel where 1" of material prior to impregnation was placed in the bottom of a box form, followed by the placement of a 4" high insulation material (polyisocyanurate) core, followed by placement of an additional 1" of material.
• the panel Upon curing, the panel was impregnated with specialized polymer to a depth of 1/2", followed by the placement of a glue line and laminate skin (HDO, resin-treated paper, wood, or synthetic material), which was applied in a pressure press machine.
• the resulting panel features are thermal insulation value of 25 "R", or greater, with a weight under 200 pounds in the 4' x 8' x 6" size. Additionally, the panel has sufficient strength to serve as a single member bearing wall for residential construction.
• the product is fire- and rot- resistant.
• Portland cement, and Celcore component are mixed to produce a final product composition having approximately 4,100 air pockets per cubic inch and a density of 25 pounds per cubic foot. Two-inch thick panels made from this composition will not decompose when exposed to 1,800°F temperature and will not decompose upon cool down from such high-temperature exposure.

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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)

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Citations (6)

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

Patent Citations (6)

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