WO2007123578A2 - Panneau de construction composite inorganique - Google Patents

Panneau de construction composite inorganique Download PDF

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Publication number
WO2007123578A2
WO2007123578A2 PCT/US2006/048012 US2006048012W WO2007123578A2 WO 2007123578 A2 WO2007123578 A2 WO 2007123578A2 US 2006048012 W US2006048012 W US 2006048012W WO 2007123578 A2 WO2007123578 A2 WO 2007123578A2
Authority
WO
WIPO (PCT)
Prior art keywords
building panel
exterior member
inorganic composite
bonded
supports
Prior art date
Application number
PCT/US2006/048012
Other languages
English (en)
Other versions
WO2007123578A3 (fr
Inventor
Jack Rigsby
Richard Wehrli
Original Assignee
21St Century Structures, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 21St Century Structures, Llc filed Critical 21St Century Structures, Llc
Priority to GB0810802A priority Critical patent/GB2448251A/en
Priority to DE112006003368T priority patent/DE112006003368T5/de
Publication of WO2007123578A2 publication Critical patent/WO2007123578A2/fr
Publication of WO2007123578A3 publication Critical patent/WO2007123578A3/fr

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Classifications

    • 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
    • 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
    • C04B28/34—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 cold phosphate binders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0092—Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard
    • 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
    • C04B28/34—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 cold phosphate binders
    • C04B28/342—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 cold phosphate binders the phosphate binder being present in the starting composition as a mixture of free acid and one or more reactive oxides
    • 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
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/06—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres reinforced
    • 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
    • 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
    • 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
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
    • 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
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49616—Structural member making
    • Y10T29/49623—Static structure, e.g., a building component
    • Y10T29/49629—Panel

Definitions

  • the present invention relates to building panels. More specifically, the presently described technology relates to an inorganic composite building panel and method and system for manufacturing thereof.
  • magnesium phosphate cements have been used as patching materials for roads.
  • magnesium phosphate cements are also used in dental applications, such as in crowns for teeth.
  • magnesium phosphate cements currently used are created in a chemical reaction that is highly exothermic. The reaction occurs at a very high reaction rate. Therefore, it is currently difficult to create large batches of magnesium phosphate cements.
  • the presently described technology provides an integrated inorganic composite building panel.
  • the building panel includes a first exterior member, a second exterior member, and a plurality of interior support members.
  • the first and second exterior members are attached to the interior support members.
  • the presently described technology also provides a method for manufacturing an inorganic composite building panel.
  • the method includes providing a plurality of interior support members and attaching the plurality of interior support members to the first and second exterior members.
  • the presently described technology also provides a system for manufacturing an inorganic composite building panel.
  • the system includes a first slurry applicator for applying cement to a plurality of fibers to produce a first exterior member, a second exterior member, and a plurality of interior support members, and an assembly unit for bonding the plurality of interior support members to said first and second exterior members.
  • Figure 1 illustrates a cross-sectional view of a chemically and/or mechanically bonded inorganic composite, according to at least one embodiment of the presently described technology.
  • Figure 2 illustrates a flow diagram of a method for manufacturing a chemically and/or mechanically bonded inorganic composite, according to at least one embodiment of the presently described technology.
  • Figure 3 illustrates a system for manufacturing a chemically and/or mechanically bonded inorganic composite, according to at least one embodiment of the presently described technology.
  • Figure 4 illustrates a cross-sectional view of a chemically and/or mechanically bonded inorganic composite building panel, according to at least one embodiment of the presently described technology.
  • Figure 5 illustrates a flow diagram of a method for manufacturing a chemically and/or mechanically bonded inorganic composite building panel, according to at least one embodiment of the presently described technology.
  • Figure 6 illustrates a system for manufacturing a chemically and/or mechanically bonded inorganic composite building panel, according to at least one embodiment of the presently described technology.
  • Figure 7 illustrates an isometric view of a chemically and/or mechanically bonded inorganic composite building panel, according to at least one embodiment of the presently described technology.
  • Figure 8 illustrates a plan view of a chemically and/or mechanically bonded inorganic composite building panel, according to at least one embodiment of the presently described technology.
  • Figure 9 illustrates an isometric view of an interior support member, according to at least one embodiment of the presently described technology.
  • Figure 1 illustrates a cross-sectional view of a chemically and/or mechanically bonded inorganic composite 100, according to at least one embodiment of the presently described technology.
  • the composite 100 includes cement 110 and a plurality of fibers 120.
  • the cement 110 can encapsulate the fibers 120.
  • the cement 110 can be attached to the fiber 120. More particularly, the cement 110 can be chemically and/or mechanically bonded to the fibers 110. Alternatively, the cement 110 can encapsulate only a portion of the fibers 120.
  • the unencapsulated fibers 120 can be attached or chemically and/or mechanically bonded to other inorganic composites 100, as described below.
  • the cement 110 can include phosphate, water, metal oxide, and filler.
  • the phosphate can include potassium phosphate (KH 2 PO 4 ) and/or ammonium phosphate, for example.
  • the metal oxide can include one or more of magnesium oxide (MgO), aluminum oxide (Al 2 O 3 ), titanium oxide (TiO 2 ), iron oxide (Fe 2 Os), calcium oxide (CaO), and/or copper oxide (CuO or Cu 2 O), for example.
  • the filler can include C fly ash, boron carbide, sand, calcium silicate, or wollastonite (CaSiO 3 ), for example.
  • the fibers 120 can include basalt, glass, ceramic, metal, carbon, and/or aramid fibers, for example.
  • the fibers 120 can be continuous or longer than a dimension of an object or structure to be formed with the composite 100. Additionally, continuous fibers can be formed into various shapes, such as a mat. Alternatively, the fibers 120 can be non-continuous or shorter than a dimension of an object or structure to be formed with the composite 100. Non-continuous fibers can include chopped fibers, for example.
  • Figure 2 illustrates a flowchart of a method 200 for manufacturing a chemically and/or mechanically bonded inorganic composite, such as the chemically and/or mechanically bonded inorganic composite 100 of Figure 1, according to at least one embodiment of the presently described technology.
  • the method 200 includes mixing phosphate with water to form a solution 210, mixing metal oxide and filler with the solution to form a slurry 220, adding fibers to the slurry 230, and curing the slurry and fiber combination to form a composite 240.
  • phosphate such as potassium phosphate (KH 2 PO 4 ) and/or ammonium phosphate
  • water H 2 O
  • phosphate such as potassium phosphate (KH 2 PO 4 ) and/or ammonium phosphate
  • KH 2 PO 4 potassium phosphate
  • H 2 O water
  • the KH 2 PO 4 can be mixed with H 2 O in a high shear mixture for about 5 to 20 minutes, for example.
  • metal oxide such as magnesium oxide (MgO), aluminum oxide (Al 2 O 3 ), calcium oxide (CaO), titanium oxide (TiO 2 ), iron oxide (Fe 2 O 3 ), and/or copper oxide (CuO or Cu 2 O)
  • filler such as C fly ash, boron carbide, sand, calcium silicate, and/or wollastonite (CaSiO 3 )
  • MgO and C fly ash can be mixed with the KH 2 PO4 solution in a high shear mixture for about 8 minutes or until a flowable slurry forms, for example.
  • fibers such as basalt, glass, ceramic, metal, carbon, and/or aramid fibers
  • fibers can be added to the slurry in a batch process.
  • basalt fibers can be placed into a mold.
  • the slurry can be poured into the mold and over the basalt fibers.
  • fibers can be added to the slurry in a continuous process.
  • a basalt fiber mat can be transported by a conveyor.
  • the slurry can be poured over the basalt fiber mat.
  • the slurry can be impregnated into the fiber mat by applying compressive force.
  • the slurry and fiber mat can pass between a plurality of rollers that apply compressive force to the slurry and mat, as described below.
  • a wetting agent can be applied to the fibers to decrease the surface tension of fibers prior to introduction into the slurry, as described below.
  • the slurry and fiber combination can be set or cured to form a chemically and/or mechanically bonded inorganic composite, such as the chemically and/or mechanically bonded inorganic composite 100 of Figure 1.
  • the slurry can cure or set in air.
  • the slurry can cure or set in water.
  • the slurry can cure or set at room temperature.
  • the slurry can cure or set at an elevated temperature.
  • An elevated temperature can include temperatures above room temperature.
  • an elevated temperature can include about 86 degrees Fahrenheit to about 110 degrees Fahrenheit.
  • one or more curing agents can be added to the ceramic composite before and/or during curing.
  • one or more of phosphoric acid, a phosphate (such as monopotassium phosphate) and a water soluble metal oxide (such as magnesium hydroxide) can be used.
  • one or more of the steps 210-240 can be performed in a vacuum, as described below.
  • Figure 3 illustrates a system for manufacturing a chemically and/or mechanically bonded inorganic composite, such as the chemically and/or mechanically bonded inorganic composite 100 of Figure 1.
  • the system 300 includes a wetting agent applicator 310, a first slurry applicator 320, a second slurry applicator 330, a plurality of rollers 340, and a conveying unit 350.
  • a mat of fiber moves through the system 300 on the conveying unit 350, such as a conveyor, as shown by direction arrows 360.
  • the mat passes under the wetting agent applicator 310.
  • the wetting agent applicator 310 continuously applies a wetting agent, such as saline, magnesium hydroxide (Mg(OH) 2 ), potassium phosphate (K 2 HPO 4 ), and/or other surfactant, to the mat.
  • the wetting agent applicator 310 can apply the wetting agent to the mat by spraying, rolling, or brushing the wetting agent onto the mat.
  • the amount of wetting agent applied to the mat can be varied by adjusting the speed at which the mat passes under the wetting agent applicator 310 (that is, the speed of the conveying unit 350) and/or by adjusting the rate at which the wetting agent is expelled from the wetting agent applicator 310.
  • the first slurry applicator 320 continuously applies a ceramic concrete or cement slurry, such as the slurry described in step 220 of Figure 2, to the mat.
  • the first slurry applicator 320 can apply the slurry to the mat by pouring, rolling, or brushing the slurry onto the mat.
  • the amount of slurry applied to the mat can be varied by adjusting the speed at which the mat passes under the first slurry applicator 320 (that is, the speed of the conveying unit 350) and/or by adjusting the rate at which the slurry is expelled from the first slurry applicator 320.
  • the rollers 340 include rounded surfaces capable of applying compressive pressure to the mat and the slurry applied by the first slurry applicator 320.
  • the rollers 340 can include a non-reactive material shaped in a cylindrical form.
  • the rollers 340 can be utilized in a manner similar to dough rollers.
  • a pair of rollers 340, each rotating in the opposite direction, can compress , the slurry and the mat. By applying pressure, the fibers in mat can be impregnated with the slurry.
  • one or more of the first slurry applicator 320 and the rollers 340 can be enclosed in a vacuum as the mat passes under and through.
  • the first slurry applicator 320 and/or the rollers 340 can be enclosed in a volume that includes an atmosphere with air pressure less than ambient air pressure.
  • the vacuum surrounding the first slurry applicator 320 and/or the rollers 340 can be a partial or total vacuum. Such a vacuum can assist with removing air pockets or voids as the fibers of the mat are impregnated with the slurry.
  • the mat, impregnated with the slurry passes under a second slurry applicator 330.
  • the second slurry applicator 330 continuously applies additional ceramic concrete or cement slurry, such as the slurry described in step 220 of Figure 2, to the mat. Similar to first slurry applicator 320, the second slurry applicator 330 can apply the slurry to the mat by pouring, rolling, or brushing the slurry onto the mat.
  • the amount of slurry applied to mat can be varied by adjusting the speed at which the mat passes under the second slurry applicator 330 (that is, the speed of the conveying unit 350) and/or by adjusting the rate at which the slurry is expelled from the second slurry applicator 330.
  • Additional slurry can be provided by the second slurry applicator 330 to provide a uniform thickness to the mat and slurry.
  • the mat and slurry can have a non-uniform thickness and/or a non-uniform surface (that is, a rough surface).
  • the final composite material can possess a more uniform thickness and/or surface.
  • the mat and slurry combination can be placed into a position of rest. In other words, the mat and slurry combination stops moving (that is, the conveying unit 350 stops moving). Once the mat and slurry combination stops moving, the ceramic concrete or cement slurry can set or cure.
  • an entire mat passes through. the system 300 before coming to rest to cure or set. Once the mat and slurry has set or cured, a chemically and/or mechanically bonded inorganic composite, such as the chemically and/or mechanically bonded inorganic composite 100 of Figure 1, is formed. The composite can then be cut to a desired length or shape.
  • the mat and slurry pass continuously through the system 300.
  • the mat and slurry combination can be cut into a desired length or shape as it passes beyond the second slurry applicator 330.
  • the mat can be cut.
  • the cut portion of the mat and slurry can then be placed in a position of rest to cure or set, as described above.
  • the ceramic concrete or cement slurry can start to cure or set before the mat is placed in a position of rest.
  • the ceramic concrete or cement slurry can start to cure or set when expelled from the first and second slurry applicators 320, 300.
  • the ceramic concrete or cement slurry can start to cure or set when mixed.
  • Figure 4 illustrates a cross-sectional view of a chemically and/or mechanically bonded inorganic composite building panel 400, according to at least one embodiment of the presently described technology.
  • the panel 400 includes a First exterior member 410, a second exterior member 420, a plurality of interior support members 430, and insulation 440.
  • the first exterior member 410, the second exterior member 420, and the interior support members 430 may be referred to as members, elements, components or trusses.
  • the panel 400 may be referred to as a panel or sheet. Additionally, the terms interior, exterior, top, bottom, front, and back can be interchangeable depending on the orientation and function of a particular embodiment of the presently described technology.
  • the first exterior member 410 can be oriented substantially parallel to the second exterior member 420.
  • the interior support members 430 can be placed between the exterior members 410, 420.
  • the supports 430 can be oriented substantially perpendicular to the exterior members 410, 420 of the building panel 400.
  • the supports 430 can be oriented at various angles to the exterior members 410, 420, for example.
  • the interior support members 430 can be attached to the first and second exterior members 410, 420.
  • the supports 430 can be chemically and/or mechanically bonded to the exterior members 410, 420 of the building panel 400.
  • the exterior members 410, 420 and supports 430 can include a chemically and/or mechanically bonded inorganic composite, such as the chemically and/or mechanically bonded inorganic composite 100 of Figure 1. However, the exterior members 410, 420 and supports 430 can include different chemically and/or mechanically bonded inorganic composites.
  • any one or more of the exterior members 410, 420 and supports 430 can include a different thickness of cement and/or volume of fiber.
  • the nominal thickness of the first exterior member or top 410 can be about 0.25 inch (0.64 centimeters).
  • the nominal thickness of the second exterior member or bottom 420 and the interior support members or trusses 430 can be about 0.25 inch (0.64 cm) to about 0.5 inch (1.27 cm), for example.
  • a thinner composite can be more cost effective (that is, less material, quicker cure), a thicker composite can provide additional compressive strength.
  • one or more of the exterior members 410, 420 and supports 430 can include a fiber volume from about 10 percent to about 40 percent. However, the fiber volume can also be larger or smaller. Although a larger fiber volume can increase the tensile strength of the composite, and thus, the component or member of the building panel, it can also result in a reduction of compressive strength.
  • one or more of the exterior members 410, 420 and supports 430 can be formed differently (that is, formed by different process and under different conditions).
  • a chemically and/or mechanically bonded inorganic composite such as the chemically and/or mechanically bonded inorganic composite 100 of Figure 1, can be formed by casting (that is, cement poured over fiber in a mold) or impregnation (that is, rollers impregnate fiber mat with cement slurry).
  • One or more of the elements or components of the building panel, particularly, the first and second exterior members 410, 420 and the interior support members 430 can include composites formed by either casting or impregnation. Composites formed by impregnation can be stronger than composites formed by casting because of reduced porosity (that is, better integration of cement and fiber).
  • the composite can be formed in atmosphere or in a vacuum.
  • one or more of the elements or components of the building panel such as the exterior members 410, 420 and the supports 430, can include composites formed in atmosphere or in a vacuum.
  • Composites formed in a vacuum can be stronger than composites formed in atmosphere because of reduced porosity, as described above.
  • the insulation 440 between the supports 430 can include air, foam, fiberglass, or cardboard, for example.
  • the chemically and/or mechanically bonded inorganic composite building panel 400 can be useful in a many different types of structures, such as residential- commercial, and industrial buildings. More particularly, the building panels 400 can include the wall panels, roof panels, and/or floor panels in a residential, commercial, or industrial building, for example. Furthermore, the building panels 400 can be stronger (in tension and/or compression) than conventional building panels, as well as lightweight and flame retardant and/or fire resistant.
  • the top of the panels typically experience a compressive load while the bottom of the panels typically experience a tensile load.
  • the composite described herein into floor and roof panels, the added tensile strength achieved by the composite allows for less total material to be used in order to achieve comparable compressive and tensile strengths.
  • the composite described herein is considerably stronger in tension than current concretes, a smaller amount of the composite can be used to achieve similar compressive and tensile strength requirements.
  • the increased tensile strength of the composite cement can provide for lighter and cheaper building panels.
  • the composite cement is stronger than traditional cements used in building panels, less of the composite cement can be used to replace traditional cements while still providing equal or greater tensile and/or compressive strengths. Therefore, by using less material to achieve the same or greater strength, the total weight of building panels made with the composite cement can be considerably lighter. Similarly, by using less material to achieve the same function, the total cost of producing a building panel decreases.
  • Figure 7 illustrates an isometric view of a chemically and/or mechanically bonded inorganic composite building panel, according to at least one embodiment of the presently described technology.
  • Figure 8 illustrates a plan view of a chemically and/or mechanically bonded inorganic composite building panel, according to at least one embodiment of the presently described technology.
  • the composite material can be used as vertical support members, or trusses, in a building panel.
  • Figure 9 illustrates an isometric view of an interior support member, according to at least one embodiment of the presently described technology.
  • the ceramic composite can be a useful replacement for vertical support members or trusses made of steel as the composite materials do not corrode (as steel does) and have increased resistance to fire (over steel).
  • Figure 5 illustrates a flow diagram of a method 500 for manufacturing the chemically and/or mechanically bonded inorganic composite building structure 400 of Figure 4, according to at least one embodiment of the presently described technology.
  • the method 500 includes providing a plurality of interior support members 510, attaching the interior support members to a first exterior member 520, providing insulation between the interior support members 530, and attaching the interior support members to a second exterior member 540.
  • interior support members such as the interior support members 430 of Figure 4
  • the supports can be prefabricated.
  • the supports can be manufactured in time with the other components of the building panel, such as the exterior members 410, 420 of the building panel 400 of Figure 4.
  • the supports can include a chemically and/or mechanically bonded inorganic composite, such as the

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Civil Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Panels For Use In Building Construction (AREA)
  • Laminated Bodies (AREA)
  • Producing Shaped Articles From Materials (AREA)

Abstract

Panneau de construction composite inorganique intégré qui comprend un premier élément externe, un second élément externe et plusieurs éléments de soutien internes. Les deux premiers éléments externes sont intégrés aux éléments de soutien internes.
PCT/US2006/048012 2005-12-16 2006-12-15 Panneau de construction composite inorganique WO2007123578A2 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB0810802A GB2448251A (en) 2005-12-16 2006-12-15 Inorganic composite building panel
DE112006003368T DE112006003368T5 (de) 2005-12-16 2006-12-15 Anorganischer Verbundstoff-Bauplatte

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US75144605P 2005-12-16 2005-12-16
US60/751,446 2005-12-16

Publications (2)

Publication Number Publication Date
WO2007123578A2 true WO2007123578A2 (fr) 2007-11-01
WO2007123578A3 WO2007123578A3 (fr) 2008-03-20

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PCT/US2006/048012 WO2007123578A2 (fr) 2005-12-16 2006-12-15 Panneau de construction composite inorganique

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Country Link
US (1) US20070261329A1 (fr)
CN (1) CN101351603A (fr)
DE (1) DE112006003368T5 (fr)
GB (1) GB2448251A (fr)
WO (1) WO2007123578A2 (fr)

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Publication number Priority date Publication date Assignee Title
DK177889B1 (en) * 2012-11-23 2014-11-17 Kim Illner Breuning System and Method for biaxial semi-prefabricated lightweight concrete slab

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GB2065742A (en) * 1979-10-03 1981-07-01 Kurimoto Ltd Glass fibre reinforced cement plates and method and apparaus for their manufacture
US5002610A (en) * 1985-12-12 1991-03-26 Rhone-Poulenc Basic Chemicals Co. Process for making reinforced magnesium phosphate fast-setting cements
US5697189A (en) * 1995-06-30 1997-12-16 Miller; John F. Lightweight insulated concrete wall
WO1998045548A1 (fr) * 1997-04-09 1998-10-15 Clear Family Limited Partnership Panneau de construction structural cimentaire

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CN101351603A (zh) 2009-01-21
GB0810802D0 (en) 2008-07-23

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