U.S. patent application number 11/627587 was filed with the patent office on 2008-07-31 for wall construction.
Invention is credited to Sam Borgia, Raymond C. Frobosilo, Melyin Lindner.
Application Number | 20080178782 11/627587 |
Document ID | / |
Family ID | 39666497 |
Filed Date | 2008-07-31 |
United States Patent
Application |
20080178782 |
Kind Code |
A1 |
Frobosilo; Raymond C. ; et
al. |
July 31, 2008 |
WALL CONSTRUCTION
Abstract
A fire resistant wall construction has inner and outer spaced
apart panels each made of at least one layer of catalyzed magnesia
cement such as DRAGONBOARD brand panels, mineral wool insulation
between the panels and a plurality of studs, such as metal studs,
connected to the panels for supporting and separating the panels
along the wall construction.
Inventors: |
Frobosilo; Raymond C.;
(Astoria, NY) ; Borgia; Sam; (Astoria, NY)
; Lindner; Melyin; (Levittown, NY) |
Correspondence
Address: |
NOTARO & MICHALOS P.C.
Suite 110, 100 Dutch Hill Road
Orangeburg
NY
10962-2100
US
|
Family ID: |
39666497 |
Appl. No.: |
11/627587 |
Filed: |
January 26, 2007 |
Current U.S.
Class: |
109/78 ;
52/582.1 |
Current CPC
Class: |
E04B 2/7411 20130101;
E04B 2/7457 20130101 |
Class at
Publication: |
109/78 ;
52/733.4 |
International
Class: |
E04B 1/94 20060101
E04B001/94; E04C 3/30 20060101 E04C003/30 |
Claims
1. A fire resistant wall construction comprising: inner and outer
spaced apart panels each made of at least one layer of catalyzed
magnesia cement, mineral wool insulation between the panels and a
plurality of studs connected to the panels for supporting and
separating the panels along the wall construction.
2. A fire resistant wall construction according to claim 1, wherein
the studs are each a metal stud.
3. A fire resistant wall construction according to claim 1, wherein
the studs are each a metal stud and are each at least partly
wrapped in gasket tape.
4. A fire resistant wall construction according to claim 1, wherein
the studs are each a metal stud and are each at least partly
wrapped in gasket tape made of polytetrafluoroethylene.
5. A fire resistant wall construction according to claim 1,
including a furring strip between at least one of the studs and a
panel for creating a space between at least one panel adjacent the
furring strip and the insulation for increasing fire
resistance.
6. A fire resistant wall construction according to claim 1,
including a furring strip made of catalyzed magnesia cement between
at least one of the studs and a panel for creating a space between
at least one panel adjacent the furring strip and the insulation
for increasing fire resistance.
7. A fire resistant wall construction according to claim 1,
including a metal track between the panels and under the
insulation.
8. A fire resistant wall construction according to claim 1,
including a furring strip made of catalyzed magnesia cement between
at least one of the studs and a panel for creating a space between
at least one panel adjacent the furring strip and the insulation
for increasing fire resistance, a metal track between the panels
and under the insulation and a further furring strip made of
catalyzed magnesia cement between the track and a panel for
creating a space between the panel and the track for further
increasing fire resistance.
9. A fire resistant wall construction according to claim 1,
including a furring strip made of catalyzed magnesia cement between
at least one of the studs and a panel for creating a space between
at least one panel adjacent the furring strip and the insulation
for increasing fire resistance, and a metal track between the
panels and under the insulation, the stud also being a metal
stud.
10. A fire resistant wall construction according to claim 1,
wherein the catalyzed magnesia cement is a mixture of an organic
base and a polyoxy(oxyalkyl)mono(X) ether blend, the alkyl group
being from 2 to 50 carbon units, the (X) group being a propyl group
or alkyl group of 25 containing carbon units, or other ether or
solvent, the blend of the base and ether being in a ratio of 1:99
to 99:1.
11. A fire resistant wall construction according to claim 1,
wherein the catalyzed magnesia cement panel is a set mixture of
inorganic magnesium compounds, pulverized wood fibers, water and
glass or synthetic fiber cloth with fine plastic fibers
therein.
12. A fire resistant wall construction comprising: inner and outer
spaced apart panels each made of at least one layer of catalyzed
magnesia cement, mineral wool insulation between the panels and a
plurality of studs connected to the panels for supporting and
separating the panels along the wall construction, the studs each
being a metal stud, and a metal track between the panels and under
the insulation.
13. A fire resistant wall construction according to claim 12,
including a furring strip made of catalyzed magnesia cement between
at least one of the studs and a panel for creating a space between
at least one panel adjacent the furring strip and the insulation
for increasing fire resistance.
14. A fire resistant wall construction according to claim 12,
wherein the studs are at least partly wrapped in gasket tape.
15. A fire resistant wall construction according to claim 12,
wherein the catalyzed magnesia cement is a mixture of an organic
base and a polyoxy(oxyalkyl)mono(X) ether blend, the alkyl group
being from 2 to 50 carbon units, the (X) group being a propyl group
or alkyl group of 25 containing carbon units, or other ether or
solvent, the blend of the base and ether being in a ratio of 1:99
to 99:1.
16. A fire resistant wall construction according to claim 12,
wherein the catalyzed magnesia cement panel is a set mixture of
inorganic magnesium compounds, pulverized wood fibers, water and
glass or synthetic fiber cloth with fine plastic fibers
therein.
17. A fire resistant wall construction comprising: inner and outer
spaced apart panels each made of at least one layer of catalyzed
magnesia cement, mineral wool insulation between the panels and a
plurality of studs connected to the panels for supporting and
separating the panels along the wall construction, the studs each
being a metal stud, a metal track between the panels and under the
insulation, and a furring strip made of catalyzed magnesia cement
between at least one of the studs and a panel for creating a space
between at least one panel adjacent the furring strip and the
insulation for increasing fire resistance, the studs being are at
least partly wrapped in gasket tape.
18. A fire resistant wall construction according to claim 17,
including a furring strip made of catalyzed magnesia cement between
each stud and each panel for creating spaces between the panels
strip and the insulation for increasing fire resistance, and a
further furring strip made of catalyzed magnesia cement between the
track and each panel for creating spaces between the panels and the
track for further increasing fire resistance.
19. A fire resistant wall construction according to claim 17,
wherein the catalyzed magnesia cement is a mixture of an organic
base and a polyoxy(oxyalkyl)mono(X) ether blend, the alkyl group
being from 2 to 50 carbon units, the (X) group being a propyl group
or alkyl group of 25 containing carbon units, or other ether or
solvent, the blend of the base and ether being in a ratio of 1:99
to 99:1.
20. A fire resistant wall construction according to claim 17,
wherein the catalyzed magnesia cement panel is a set mixture of
inorganic magnesium compounds, pulverized wood fibers, water and
glass or synthetic fiber cloth with fine plastic fibers therein.
Description
FIELD AND BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to the field of
residential and commercial building, and in particular to a new and
useful wall construction that has various improved attributes,
including increased fire-resistance.
[0002] Sorel cement is a hydraulic cement mixture of magnesium
oxide with magnesium chloride together with filler materials like
sand or crushed stone. The usual weight ratio is 2.5 to 3.5 parts
MgO to one part MgCl.sub.2 and this material is also called
magnesia cement. A major drawback of this type of cement is its
poor resistance to water which makes it unsuitable for use as a
drywall component.
[0003] U.S. Pat. No. 6,773,794 to Lindner, which is incorporated
here by reference, teaches a construction panel having a small
amount of plastic fibers mixed with inorganic magnesium compounds,
water and other substances to be extruded to form a synthetic
construction panel will significantly reduced slumping. This patent
also discloses the use of a catalyst such as urea and
poly(oxypropylene)monomethyl ether which causes a reaction in the
otherwise water sensitive magnesia cement to render it water
resistant and therefore better suited for use as a construction
component.
[0004] Traditional wall board is made of gypsum, a soft mineral
composed of calcium sulfate. While wall constructions using gypsum
wall board have some fire resistance, in order to achieve
recognized levels of fire resistance that are rated in hours, such
as a 2, 3 or 4 hour wall, multiple layers of gypsum wall board must
be used.
[0005] Mineral wool insulation, as opposed to conventional
fiberglass insulation, typically refers to two types of insulation
material, namely rock wool, a man-made material consisting of
natural minerals like basalt, or diabase or slag wool, a man-made
material from blast furnace slag (the scum that forms on the
surface of molten metal). See, for example, products available at
http://www.specjm.com/mineral-wool.php or
http://www.rockwool.com/enrock/mineral_wool_insulation.asp.
SUMMARY OF THE INVENTION
[0006] It is an object of the present invention to provide a fire
resistant wall construction that used inner and outer spaced apart
panels that are each made of at least one layer of catalyzed
magnesia cement, with mineral wool insulation in the space between
the panels and a plurality of studs connected to the panels for
supporting and separating them along the wall construction.
[0007] The fire resistant attribute of the wall construction of the
invention can be augmented further by various additional feature
that will be disclosed in greater detail here.
[0008] The various features of novelty which characterize the
invention are pointed out with particularity in the claims annexed
to and forming a part of this disclosure. For a better
understanding of the invention, its operating advantages and
specific objects attained by its uses, reference is made to the
accompanying drawings and descriptive matter in which a preferred
embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] In the drawings;
[0010] FIG. 1 is a perspective cut-away view of one embodiment of
the invention for providing a rating of 2 hour fire resistance;
[0011] FIG. 2 is a sectional view of the wall construction of FIG.
1;
[0012] FIG. 3 is a view similar to FIG. 1 but of a wall
construction of the invention for providing a 3 hour fire
resistance rating; and
[0013] FIG. 4 is a sectional view of the wall construction of FIG.
3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Referring now to the drawings, in which like reference
numerals are used to refer to the same or similar elements, FIG. 1
shows a fire resistant wall construction 10, comprising an inner
panel 12 and an outer panel 14 spaced by 4 inches from the inner
panel to create a space 16. The spacing may be from 2 to 6 inches.
Each panel is made of at least one layer of what is referred to
here as catalyzed magnesia cement, exemplified by 10 or 14 mm (or
9/16 inch) DRAGONBOARD brand wall board. Mineral wool insulation 18
in bat, rigid panel or loose fill form, is provided in the space 16
between the panels 12 and 14, and a plurality of studs 20 are
connected, e.g. by drywall screws 22, to the panels for supporting
and separating the panels along the wall construction 10.
[0015] The commercially available wall board product made of
inorganic magnesium compounds and marketed under the registered
trademark DRAGONBOARD is meant to become a substitute for
traditional drywall. Details about this product can be found at
http://www.dragonboard.com. These details and the use of
DRAGONBOARD brand wall board as a non-limiting example of catalyzed
magnesia cement for the fire resistant wall construction of the
present invention, were published after the date of the subject
invention and within one year of the filing date of the subject
application for patent. The term catalyzed magnesia cement is used
here to mean any Sorel cement that has been subjected to a
catalyzed reaction, like the one disclosed in U.S. Pat. No.
6,773,794 to Lindner for example, or other reactions using other
catalysts to render it water resistant.
[0016] Returning again to FIG. 1, the studs 20 can be conventional
wood studs, e.g. 2.times.3 or 2.times.4 studs, or preferably are
each a metal stud of bent 18 or 20 ga. galvanized sheet steel
having an in-bent flange 24 at each side for embracing the
insulation 18 that extends into the hollow of each stud.
[0017] The studs are each at least partly wrapped in gasket tape
26, such as gasket tape made of polytetrafluoroethylene, especially
where the insulation will touch the stud. A metal track 28 is
provided between the panels and under the insulation as well.
[0018] Referring now to FIGS. 3 and 4, a three (3) hour wall
construction of 10 of the present invention includes the features
of the construction 10 in FIGS. 1 and 2, but also includes a 3 inch
wide furring strip 30 of the same catalyzed magnesia cement as the
panels 12 and 14, placed between at least one, but preferably both
sides or all of the studs 20 and the adjacent panels 12 and 14 for
creating a space between each panel and the insulation for further
increasing fire resistance. Similar furring strips 32, e.g. 2
inches tall are between each panel 12 and 14 and each side of the
track 28. The furring strips like the panels are fixed in place by
drywall screws 22.
[0019] For even further increased fire resistance, e.g. for a four
(4) hour rating, two layers of catalyzed magnesia cement 12 and 14
are provided as each panel. This compares to the four (4) gypsum
drywall panels that would be needed on each side of the wall for
the same fire rating, or the two (2) gypsum drywall layers on each
side that would be needed for three or even two hour fire
ratings.
[0020] The gasket tape 26 may be made for example of
polytetrafluoroethylene (PTFE) commonly known by its trademark
TEFLON, used to wrap all or part of each metal stud in each
embodiment although other gasket tape material can be used.
[0021] The terms "inner" and "outer" are used for convenience only
and may be reversed or may designate upper and lower panels since
the wall construction of the invention can also be used for
ceilings as well.
[0022] Although a preferred composition of this catalyst for the
catalyzed magnesia cement is the one disclosed in U.S. Pat. No.
6,773,794 to Lindner, others that are known or are to be discovered
by those skilled in the at may also be used to characterize this
catalyzed magnesia cement of the present invention.
[0023] The catalyst may be of the following general composition,
for example: a mixture of an organic base and a
Polyoxy(oxyalkyl)mono(X) ether blend, the alkyl group being from 2
to 50 carbon units, the X group being a propyl group or alkyl group
of 25 containing carbon units, or any other ether or solvent
suitable. The blend of the base and ether can be 1:99 or the
reverse.
[0024] The a construction panel may be a mixture of inorganic
magnesium compounds, pulverized wood fibers, water and glass or
synthetic fiber cloth which is formed as an edged layer and is
permitted to set, with a small amount of fine plastic fibers,
thereby to minimize slumping of the layer at its edges during
setting.
[0025] While specific embodiments of the invention have been shown
and described in detail to illustrate the application of the
principles of the invention, it will be understood that the
invention may be embodied otherwise without departing from such
principles.
* * * * *
References