U.S. patent application number 12/292879 was filed with the patent office on 2009-05-28 for high-performance environmentally friendly building panel and related manufacturing methods.
This patent application is currently assigned to Southern Cross Building Products, LLC. Invention is credited to Rodrigo Vera.
Application Number | 20090133361 12/292879 |
Document ID | / |
Family ID | 40668557 |
Filed Date | 2009-05-28 |
United States Patent
Application |
20090133361 |
Kind Code |
A1 |
Vera; Rodrigo |
May 28, 2009 |
High-performance environmentally friendly building panel and
related manufacturing methods
Abstract
Various embodiments of a high-performance environmentally
friendly building panel and related manufacturing methods are
disclosed. Certain example embodiments described herein relate to
various high-performance building panel configurations that utilize
at least one engineered mixture produced with a desired thickness,
shape and dimension, and manufactured through several preferential
manufacturing methods. To selectively enhance some of the
high-performance building panel characteristics such as its ability
to withstand significant loads, mitigate possible contamination by
bacteria growth, as well as its ability to be fire-retardant or
fire-suppressant, and other credible operating scenarios the
characteristics of different engineered mixtures may be combined
during the panel forming process. Some of the manufacturing steps
may involve sterilization and utilization of light-sensitive
chemicals so as to sterilize as well as to enhance certain
thermal-physical and mechanical characteristics of the
high-performance building panel.
Inventors: |
Vera; Rodrigo; (Delray
Beach, FL) |
Correspondence
Address: |
NIXON & VANDERHYE, PC
901 NORTH GLEBE ROAD, 11TH FLOOR
ARLINGTON
VA
22203
US
|
Assignee: |
Southern Cross Building Products,
LLC
Boynton Beach
FL
|
Family ID: |
40668557 |
Appl. No.: |
12/292879 |
Filed: |
November 28, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60996588 |
Nov 27, 2007 |
|
|
|
Current U.S.
Class: |
52/794.1 ;
52/745.19 |
Current CPC
Class: |
E04C 2/044 20130101;
B32B 2262/101 20130101; B32B 5/022 20130101; B32B 2307/58 20130101;
B32B 2607/00 20130101; B32B 2307/50 20130101; B32B 2419/06
20130101; B32B 13/02 20130101; B32B 13/14 20130101; B32B 9/005
20130101; B32B 2307/7265 20130101; B32B 2250/40 20130101; B32B 5/26
20130101; B32B 2419/04 20130101; B32B 2419/00 20130101; B32B 5/30
20130101; B32B 5/16 20130101; B32B 2307/3065 20130101; B32B
2307/718 20130101; B32B 2307/546 20130101; B32B 2307/7145 20130101;
B32B 7/12 20130101 |
Class at
Publication: |
52/794.1 ;
52/745.19 |
International
Class: |
E04B 1/92 20060101
E04B001/92 |
Claims
1. A building panel comprising: a core mix; and one or more fillers
or binders, including at least about 2-3% by weight of glass.
2. The building panel of claim 1, wherein the glass takes the form
of recycled glass beads.
3. (canceled)
4. A building panel comprising: a core mix; and one or more fillers
or binders, including little or no Perlite.
5. A building panel comprising: a core mix; and one or more fillers
and/or binders, including little or no silica.
6. The building panel of claim 5, wherein the silica comprises no
more than about 2% by weight of the composition.
7. The building panel of claim 5, wherein the core mix comprises
70-85% by weight of the composition, with the balance in said
fillers and/or binders.
8. The building panel of claim 5, wherein the core mix comprises
MgO and MgCl.sub.2.
9. The building panel of claim 5, wherein the fillers and/or
binders include a light-radiation-sensitive compound.
10. The building panel of claim 5, further comprising
microspheres.
11. The building panel of claim 10, wherein the microspheres may be
coated or uncoated and filled or unfilled.
12. An apparatus for manufacturing a building panel, comprising: at
least one main reactor including a plurality of tanks, each said
tank including a tank mixture material; a mixer to receive the tank
mixture material from each of the tanks and to provide a mixture of
materials collected from all of the tanks; a conveyer surface to
receive the mixture of materials from the mixer and to form the
mixture into a board having a predetermined shape; a curing unit to
receive the board from the conveyer surface; and a controller to
control environmental processing conditions in the main reactor,
the mixer and/or the conveyer.
13. (canceled)
14. The apparatus of claim 12 wherein the environmental processing
conditions include temperature, humidity and/or pressure.
15. The apparatus of claim 12 further comprising a heating/cooling
unit provided to the conveyer surface, wherein the controller is
set to control the heating/cooling unit.
16. The apparatus of claim 12 further comprising at heater provided
to each of the tanks, wherein the controller is set to control the
heater of each of the tanks.
17. The apparatus of claim 12 further comprising a heating/cooling
unit provided to the mixer, wherein the controller is set to
control the heating/cooling unit.
18. The apparatus of claim 12 wherein the pressure inside each of
the tanks is controllable by the controller.
19. The apparatus of claim 12 wherein the mixer includes a
pressurizer controllable by the controller.
20.-22. (canceled)
23. The apparatus of claim 12 further comprising a diffuser to
spread the mixture of materials onto the conveyer surface.
24. The apparatus of claim 23 wherein the temperature and/or
pressure inside the diffuser are controllable by the
controller.
25.-26. (canceled)
27. The apparatus of claim 12 further comprising at least one roll
placed above the conveyer surface.
28.-29. (canceled)
30. The apparatus of claim 12 further comprising a light or
electron beam source to irradiate and/or sterilize the mixture of
materials along the path of the conveyer surface.
31.-34. (canceled)
35. The apparatus of claim 12 further comprising a lubricating
system, controllable by the controller, to lubricate the conveyer
surface prior to application of the mixture of materials on the
conveyer surface.
36.-45. (canceled)
46. A method for manufacturing a building panel, comprising:
providing at least one main reactor including a plurality of tanks,
each said tank including a tank mixture material; providing a mixer
to receive the tank mixture material from each of the tanks and to
provide a mixture of materials collected from all of the tanks;
providing a conveyer surface to receive the mixture of materials
from the mixer and to form the mixture into a board having a
predetermined shape; providing a curing unit to receive the board
from the conveyer surface; and controlling, via a controller,
environmental processing conditions in the main reactor, the mixer
and/or the conveyer.
47. (canceled)
48. The method of claim 46 wherein the environmental processing
conditions include temperature, humidity and/or pressure.
49. The method of claim 46 further comprising a heating/cooling
unit provided to the conveyer surface, wherein the controller is
set to control the heating/cooling unit.
50. The method of claim 46 further comprising at heater provided to
each of the tanks, wherein the controller is set to control the
heater of each of the tanks.
51. The method of claim 46 further comprising a heating/cooling
unit provided to the mixer, wherein the controller is set to
control the heating/cooling unit.
52. The method of claim 46 wherein the pressure inside each of the
tanks is controllable by the controller.
53. The method of claim 46 wherein the mixer includes a pressurizer
controllable by the controller.
54.-56. (canceled)
57. The method of claim 46 further comprising a diffuser to spread
the mixture of materials onto the conveyer surface.
58. The method of claim 57 wherein the temperature and/or pressure
inside the diffuser are controllable by the controller.
59.-60. (canceled)
61. The method of claim 46 further comprising at least one roll
placed above the conveyer surface.
62. The method of claim 61 wherein the at least one roll includes a
heating/cooling element controllable by the controller.
63. (canceled)
64. The method of claim 46 further comprising a light or electron
beam source to irradiate and/or sterilize the mixture of materials
along the path of the conveyer surface.
65.-68. (canceled)
69. The method of claim 46 further comprising a lubricating system,
controllable by the controller, to lubricate the conveyer surface
prior to application of the mixture of materials on the conveyer
surface.
70.-79. (canceled)
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. provisional
application Ser. No. 60/996,588, filed on Nov. 27, 2007,
incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] Certain example embodiments described herein relate to
several distinct panel-forming mixtures and manufacturing
unassembled elements which, when assembled, result in an efficient
and cleaner manufacturing process dedicated to the production of
functional, low-cost, highly-performing, and environmentally
friendly building panels. More particularly, certain example
embodiments described herein relate to various panel-forming
mixtures and manufacturing configurations that may utilize multiple
distinct mixtures comprising chemical elements which when combined,
at the proper temperature and pressures, accurately and repeatedly
generate an engineered mixture ready to be poured or pressure
injected into a shape-forming and curing system. Once the
engineered mixture is poured, or pressure injected, into an
adjustable shape-forming and curing system it undergoes a series of
processes wherein temperature and pressure may be controlled so as
to optimize the production efficiency while maintaining the highest
finished panel quality. Curing of the engineered mixture may begin
from the moment it is poured, or pressure injected, into the
shape-forming system by surface or in-depth exposure to controlled
selective wavelengths of light, for example ultra-violet radiation,
as well as other forms of radiation. Wavelength, intensity, and
energy deposited by these various form of radiations may be
adjusted so as to penetrate different thicknesses of distinct
mixtures and selectively cure layers of the panel during formation
and manufacturing. Exposure to these forms of radiation also
sterilizes the high-performance building panel.
[0003] The distinct mixtures may be pre-mixed in mixture selecting
and filtering tanks wherein active components such as, for example,
electrical heaters, pressurizers, mixture positive displacement
pumps, and stirring elements may be activated and monitored via
specialized sensors. By actively controlling the thermodynamic
parameters of the chemicals being mixed the speed at which the
final construction board is being produced is fine tuned and
optimized at all times, while obtaining a high quality and reliable
product. Accurate and active control of the distinct mixtures
improves their reaction rates and efficiency while assuring the
generation of desired distinct mixtures densities and viscosities
prior to being poured, or pressure injected, into the shape-forming
and curing system.
BACKGROUND AND SUMMARY OF EXAMPLE EMBODIMENTS OF THE INVENTION
[0004] Methods dedicated to the production of construction-panels
with enhanced mechanical, fire resistant, and water proof
characteristics have been known for several years. In some
applications desired construction-panel geometries may be achieved
by pouring various mixtures into fixed geometry forms wherein the
mixture is uniformly spread with a controlled thickness, and
allowed to cure for several hours. During the curing process the
water in the mixture evaporates while permanent chemical bonds form
and give the construction-panel desired material characteristics
such as ability to withstand deformation, load, contamination,
corrosion, and so on. In most of the methods adopted the curing
process is executed at ambient pressures, temperatures, and
humidity. Some of these mixtures comprise water mixed with
magnesium oxide, magnesium chloride, wood shaving, perlite and
other binding agents, as indicated, for example, in U.S. Pat. No.
7,255,907. Several of the final product physical characteristics
depend on how these compounds are mixed, their relative percentage,
and their curing time. In U.S. Pat. No. 7,255,907, for example,
curing is executed under the variability and uncontrollability of
environmental pressure and temperature conditions, and the addition
of perlite in large proportions results in a final product
generally very hard, brittle, difficult to cut, and with generally
rough surfaces. In addition, the final product may need to be cured
for several hours or days inside fixed forms. Variability of the
weather conditions (i.e. sunny dry days versus high humidity rainy
days) may result with variable enhanced or deteriorated mechanical
characteristics of the final product also affecting the panel
surface roughness, and stability of its shape. In some other
applications fire-resistant fabrics or fiber meshes are applied to
the surfaces of the construction panel while being formed resulting
in a fire resistant barrier as indicated, for example, on US patent
application publication No. 2006/0070321 A1. However, in some of
these applications there is still uncertainty in their long-term
stability as warping, or repeated cyclic stresses, impact, and so
on can cause layers to separate and delamination of the layers
exposed to the environment may occur. Some other mixtures include
reactive materials such as metal oxide(s), phosphate(s), and
residual materials to which may be added a reactive foaming agent
so as to form lightweight composites as indicated, for example, on
patent application publication No. US 2005/0252419 A1. The
objective in this case is that of providing building materials with
enhanced thermo-physical properties. In these cases controlling the
expansion of the "reactive" mixture is difficult and maintaining a
desired geometric shape during the curing of the mixture requires
complex and expensive methodologies. In addition these
manufacturing processes may produce large amounts of green-house
gases.
[0005] Generally, products manufactured with high percentages of
perlite are rigid and brittle, thereby prone to cracking, they are
heavy and hard to cut, especially with a utility blade. In
addition, prior art manufacturing methods require relatively long
curing times.
[0006] Therefore, it will be appreciated that it would be
beneficial to provide high-performance, environmentally friendly,
lighter building panels, easier to cut, more resistant to
mechanical stresses, and whose manufacturing processes require less
curing time. In addition, the high-performance building panel of an
example of the present invention is flexible as, for example, it
may be used in contoured environments such as curved walls,
substrate for paneling, siding, or roofing shingles, and for
various applications, including marine applications.
[0007] The manufacturing methods described herein utilize recycled
materials, and/or minimize, or eliminate, the usage of perlite or
silicates, or other aggregates which may have negative
environmental or health-related consequences. Materials as perlite,
or other aggregates can be replaced by recycled glass (e.g., glass
beads), and/or micro-sphere based or inert materials so as to
reliably provide high-quality, cost-effective, and environmentally
friendly building panels.
[0008] Therefore, the utilization of perlite may be reduced or
eliminated by substituting it with recycled industrial glass, for
example, made into a powder forms and mixed with certain engineered
mixtures of the present invention. Alternatively, or in addition,
recycled or engineered ceramic powder may be used. In this manner
the resulting building panels show enhanced thermal-physical,
mechanical, fire, water, and bacterial growth resistance
characteristics. The methods described herein do not rely on fixed
geometry forms as the engineered mixture, once brought to the
desired thickness and proper rigidity, may be cut to adjustable
shapes and dimensions, thereby allowing separation, and later
curing in a racking system. In addition, the ambient conditions
surrounding the now separated curing panel(s), cured when stationed
within the racking system, may be controlled so as to enhance
production rates, and quality assurance.
[0009] According to one example embodiment of the invention, there
is provided a building panel comprising a core mix; and one or more
fillers or binders, including at least about 2-3% by weight of
glass. The glass may take the form of recycled glass beads.
[0010] According to another example embodiment of the invention,
there is provided a building panel comprising a core mix; and one
or more fillers or binders, including at least about 2-3% by weight
of an anti-microbial or anti-fungal.
[0011] According to another example embodiment of the invention,
there is provided a building panel comprising a core mix; and one
or more fillers or binders, including little (e.g., less than about
3%) or essentially no Perlite.
[0012] According to another example embodiment of the invention,
there is provided a building panel comprising a core mix; and one
or more fillers and/or binders, including little (e.g., less than
about 2%, or less than 1%) or essentially no silica. The core mix
may comprise 70-85% by weight of the composition, with the balance
in said fillers and/or binders. The core mix may comprise MgO and
MgCl.sub.2.
[0013] According to another example embodiment of the invention,
there is provided an apparatus for manufacturing a building panel,
comprising at least one main reactor including a plurality of
tanks, each said tank including a tank mixture material; a mixer to
receive the tank mixture material from each of the tanks and to
provide a mixture of materials collected from all of the tanks; a
conveyer surface to receive the mixture of materials from the mixer
and to form the mixture into a board having a predetermined shape;
a curing unit to receive the board from the conveyer surface; and a
controller to control environmental processing conditions in the
main reactor, the mixer and/or the conveyer.
[0014] According to another example embodiment of the invention,
there is provided a method for manufacturing a building panel,
comprising providing at least one main reactor including a
plurality of tanks, each said tank including a tank mixture
material; providing a mixer to receive the tank mixture material
from each of the tanks and to provide a mixture of materials
collected from all of the tanks; providing a conveyer surface to
receive the mixture of materials from the mixer and to form the
mixture into a board having a predetermined shape; providing a
curing unit to receive the board from the conveyer surface; and
controlling, via a controller, environmental processing conditions
in the main reactor, the mixer and/or the conveyer.
[0015] According to certain example embodiments, a high-performance
environmentally friendly building panel and related method are
provided. The aspects and embodiments of this invention may be used
separately or applied in various combinations in different
embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] These and other features and advantages may be better and
more completely understood by reference to the following detailed
description of exemplary illustrative embodiments in conjunction
with the drawings, of which:
[0017] FIG. 1 is a schematic illustration of a high-performance
environmentally friendly building panel showing some simplified
manufacturing steps in accordance with an example embodiment;
[0018] FIGS. 2 is a simplified schematic illustration of selected
manufacturing steps wherein the engineered mixture is poured, or
pressure injected, onto a substantially flat surface in accordance
with an example embodiment;
[0019] FIG. 3 is schematic illustrations showing the substantially
flat surface with an inclinable slope in accordance with an example
embodiment;
[0020] FIG. 4 is a schematic illustration of the high-performance
environmentally friendly building panel manufacturing steps
including the cutting, thickness fine adjustment system, and final
curing processes by positioning the resulting high-performance
building panel into an environmentally controlled racking system,
in accordance with an example embodiment;
[0021] FIG. 5 is a schematic illustration showing multiple reactor
mixers configured so as to combine distinct engineered mixtures
forming layers to enhance the overall building panel material and
mechanical properties, in accordance with an example
embodiment;
[0022] FIG. 6 is a cross-sectional view of a simplified
manufacturing method configuration including a continuous
production method adopting a moving substantially flat surface
wherein the engineered mixture is poured or pressure injected, in
accordance with an example embodiment;
[0023] FIG. 7 is a cross-sectional view of a simplified
manufacturing method configuration including a continuous
production method adopting a moving substantially flat surface
wherein the engineered mixture is poured or pressure injected into
a controlled environment as the whole process occurs within
temperature, pressure and humidity control, in accordance with an
example embodiment;
[0024] FIG. 8 is a top view representation of a multilayer
manufacturing process wherein layers can be shaped according to
different patterns so as to achieve different mechanical, fire
retarding or suppressing characteristics, in accordance with an
example embodiment;
[0025] FIG. 9 is a representation of the surface of the
high-performance building panel wherein by means of a special
roller, or a dedicated form, a characteristic pattern, for example
three-dimensional wood patterns, may be molded onto the building
panel surface during the manufacturing processes, in accordance
with an example embodiment;
[0026] FIG. 10 is a cross sectional schematic of a single or
multilayered building panel wherein coated or un-coated
micro-spheres may be part of the engineered mixture so as to
enhance selected characteristics of the building panel, in
accordance with an example embodiment; and,
[0027] FIG. 11 (Table 1) provides an example list of chemical
elements in relation to one another and their ratio whose
combination forms optimized engineered mixtures assembled,
processed, and cured through various manufacturing methods to
provide high-performance panels of different thicknesses and
geometric dimensions, according to example embodiments.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS OF THE INVENTION
[0028] The following description is provided in relation to several
embodiments which may share common characteristics and features. It
is to be understood that one or more features of any one embodiment
may be combinable with one or more features of the other
embodiments. In addition, any single feature or combination of
features in any of the embodiments may constitute additional
embodiments. 100291 Referring now more particularly to the drawings
in which like reference numerals indicate like parts throughout the
several views, FIGS. 1-6 are schematic illustrations of a
high-performance environmentally friendly building panel and
related manufacturing methods in accordance with an example
embodiment.
[0029] In FIG. 1, a preferential manufacturing method for the
high-performance environmentally friendly building panel is shown.
In this Figure a main reactor I a represents a controlled chemical
system wherein different chemical compounds may be mixed in
distinct tanks 1, 2, and 3. Tank 1 may contain, for example,
approximately 22% of MgCl.sub.2 and H.sub.2O, as indicated by A and
B respectively. Tank 2 may contain MgO, as indicated by E, and
recycled industrial glass, ceramic, or perlite powder as indicated
by D. Tank 3 may contain additional mixing material such as spelt,
recycled glass powder, ceramic powder, and micro-spheres as
indicated by C. Mixing of compounds A, B, D and E is executed at
proper pressure and temperature, e.g., about 68.degree.-75.degree.
F., as well as filtering of impurities may be executed within their
corresponding Tank (as shown in Tank 3 by filtering system 4).
Temperature and pressures inside Tank 1 may be monitored with
temperature sensors or transducers and pressure sensors or
transducers, and controlled via computer and data acquisition
system or controller 27, which may take the form of a general
purpose computer. This computerized system may be configured to
control and actuate one or more electrical heaters 1b so as to
assure uniform temperature distributions, e.g., about
68.degree.-75.degree. F. within the mixture this tank contains.
Similarly for Tank 2, actuation of one or more electrical heaters
2a assures uniform temperature distribution across the mixtures
contained within the tank's inner walls. Tanks 1, 2, and 3 may be
pressurized, e.g., about 14-25 psi, to avoid premature water
evaporation at higher operating temperatures.
[0030] Once mixing of the distinct compounds A, B, C, D, and E in
each separated tank is completed they are merged into a final mixer
6 wherein a stirring device 6b assures uniform blending at
controlled temperature, e.g., about 72.degree.-75.degree. F., and
pressures. Process temperatures inside final mixer 6 may be
controlled by actuating one or more heating or cooling elements 5
(i.e. through representative leads 5a and 5b), e.g., about
68-75.degree. F., while the pressure is controlled by a pressurizer
7, e.g., about 25-35 psi. Depending on the type of chemical
reactions, once all of the distinct mixtures are blended, in some
cases they may generate heat, in which case heat removal is
required (i.e. via cooling coils, not shown in FIG. 1), in other
cases the reactions require heat, in which case heating elements
are activated (i.e. heating element(s) 5.
[0031] Pressurizer 7 may be configured to contain a controlled
amount of water and full immersion heaters. Activation of the
heaters causes pressurization of the final mixer 6 inner chamber.
Alternative methods of pressurization (i.e. via positive
displacement pumping device) may also be used. All of the active
components are monitored and actuated by the computerized system
27. 10033J Timely opening and closing of valves 28, 29, and 30
assures a desired ratio between distinct mixtures A+B, C, and D+E
originally prepared in their distinct tanks 1, 3, and 2
respectively. The timely and calibrated opening of valves 28, 29
and 30 may be executed manually, or automatically. When the system
operates in automatic mode these valves may be actuated by the
computerized system 27. Inside final mixer 6 water content is also
monitored to assure the viscosity, e.g., about 8,000-12,000 mPa of
the resulting engineered mixture (A+B+C+D+E) is accurately
controlled.
[0032] Once the engineered mixture is ready inside the final mixer
6 a positive displacement pumping system 6a is actuated. At the
pumping system 6a suction, or inlet, the engineered mixture flows
inside the pumping system by gravity and by pressure difference.
Once inside the positive displacement pumping system 6a the
engineered mixture is compressed to a controlled pressure, e.g.,
about 25-35 psi, and maintained at a pre-determined design
pressure, e.g., about 30-35 psi. When valve 8 is actuated the
engineered mixture flows inside diffuser 9. The inner walls of
diffuser 9 may be actively heated (not shown in FIG. 1). When the
pressure inside diffuser 9 reaches a proper threshold, e.g., about
35-45 psi, a spring-loaded gate 9c, acting as a check valve, begins
opening and pouring or, depending on the manufacturing methods
desired, pressure injecting a pre-shaped engineered mixture 14 onto
layers of non-woven and fiber-glass materials positioned between a
heated or cooled substantially flat surface 17 and the pre-shaped
engineered mixture 14 by means of spools 10 and 11. The shape of
the diffuser 9 outlet may be designed to provide the engineered
mixture with a pre-shaped geometric form. Means to actively control
and adjust the diffuser 9 outlet geometry may also be provided.
100351 Curing of the pre-shaped engineered mixture 14 may be
accelerated by regulating the temperature of the substantially flat
conveyer surface 17, through actuation of properly distributed
heating or cooling elements 26, as well as the temperature of rolls
15, and 16. These rolls may be equipped with active heating or
cooling elements so as to assure uniform and constant pre-selected
temperature on their surfaces. Although, not shown in FIG. 1 and in
all other representation from FIG. 2-FIG. 6, the entire process may
occur at a controlled environmental pressure and humidity, e.g.,
about 65-75% (absolute humidity), so as to counterbalance, for
example, the increased water evaporation due to the adoption of
reaction rate accelerating heaters. In addition, rollers 15 and 16
may increase or decrease the thickness of the pre-shaped engineered
mixture 14 by actuation of systems 15a and 16a wherein their
position may be hydraulically, motor, or electromagnetically
actuated, for example via computerized system 27.
[0033] Tank 3 may also provide the engineered mixture with
light-radiation-sensitive compounds which may be used to change
shape or density when irradiated. In this case, while the
pre-shaped engineered mixture 14 is poured or pressure injected
onto the non-woven and fiber-glass layers properly positioned onto
the substantially flat heated surface 17, a source 25 emitting
light at proper wavelength, e.g., about 750-900 nm, may irradiate
the pre-shaped engineered mixture 14. In this manner the pre-shaped
engineered mixture 14 curing can be made so as to selectively
enhance certain physical and thermal characteristics of the final
product and provide a very high-performance and environmentally
friendly building panel.
[0034] Source 25 may also represent an electron beam radiation
source so as to irradiate and sterilize the engineered mixture.
[0035] After the first set of active rollers 15 additional layers
of non-woven and fiber-glass materials are positioned onto the
pre-shaped engineered mixture 14 by means of spools 12 and 13.
Final thickness adjustments may be accomplished by active rollers
systems 16. Temperature on the surfaces of rollers 16 may be
regulated, e.g., about 75.degree.-80.degree. F., so as to "melt" or
increase bonding of different materials (i.e. other than
fiber-glass) onto the pre-shaped engineered mixture 14.
[0036] The substantially flat temperature controlled surface 17 may
be stationary or movable and it can move at the same speed of the
moving pre-shaped engineered mixture 14, or at different
speeds.
[0037] The substantially flat temperature controlled surface 17 may
also be inclined by a desired angle indicated by a with respect to
the horizon so as to use the aid of gravity force when the process
involves, for example, engineered mixtures with high viscosity.
[0038] A preferential high-performance environmentally friendly
building panel manufacturing method is shown in FIG. 2. In this
representation the engineered mixture 14 is poured or pressure
injected onto a stationary or movable substantially flat heated or
cooled surface 17. Active and fine dimensioning of the pre-shaped
engineered mixture 14 may be achieved by actuating side actuators
17d and 17e. The system is symmetrical and the process is equipped
with similar actuators on both sides (for simplicity not shown in
FIG. 2). To avoid adherences of the surface materials utilized to
cover the pre-shaped engineered mixture 14 a lubricating system 18
may provide lubricating or reactive, curing, fluids 18a directly on
the substantially flat heated or cooled surface 17 and/or on the
spools 10 or 11. Controller 27 may provide a control signal to
activate system 18, e.g., by monitoring, via a proximity sensor,
whether the mixture 14 has been deposited or injected onto surface
17, and controlling the system 18 to apply fluid to the surface for
a predetermined period of time or until such time as the mixture is
applied to the surface.
[0039] The computerized system 27 of FIG. 1, may control and
actuate cutting blade 20 so as to cut the curing high-performance
building panel with adjustable and desired dimensions. The
substantially flat heated or cooled flat surface 17 may be
configured so as to slide over a fixed surface 17c and move at
speeds proportional to that of the poured or injected engineered
mixture 14.
[0040] In FIG. 3 another manufacturing method similar to that
described in FIG. 2 is shown. In this figure the substantially flat
heated or cooled surface 17 may be stationary with respect to the
poured or pressure injected pre-shaped engineered mixture 14,
however, it may be inclined with different slopes as determined by
actuation of actuator 17b. In this case the pre-shaped engineered
mixture 14 may show different degrees of viscosity, for example, to
satisfy the requirements of specialized applications.
[0041] In FIG. 4 the final process steps of a preferential
high-performance building panel manufacturing method are shown. In
these steps, the high-performance panel obtained by processing the
pre-shaped engineered mixture 14 is advanced and an "end strip" 21
of proper materials, e.g., extruded graphite, is placed at the edge
of the building panel prior to its final thickness check by means
of active rollers 16' and relative lubricating or curing fluids
sprayed by sprayer 22, and prior to the building panel 23 entering
a controlled racking system positioned within a controlled
environment chamber 24. Heat, humidity and pressure are actively
controlled, for example, by means of drying heaters 24a, steam
generators 24b, and a pressurizer 24c, e.g., pressure is maintained
up to about 40 psi.
[0042] In FIG. 5 a preferential method for the manufacturing of
highly-performing, environmentally friendly universal building
panels is shown. In this figure more than one reactor 1a (as shown
in FIG. 1) is employed so as to create two or more distinct layers
as an integral part of a single building panel. This method
considers three distinct reactors 1a, 1b, and 1c, however it can
use two or more than three. In this preferential building panel
manufacturing method reactor 1a may be configured to pour or
pressure inject a distinct engineered mixture 14, designed to
provide extremely resilient characteristics, for example, in terms
of rigidity, or fire resistance, or others. Reactor 1b may be
configured to pour or pressure inject a different and distinct
engineered mixture 14a designed, for example, to provide
significant impact resistance characteristics, or show high levels
of flexibility, or with extremely low thermal conductivities.
Finally reactor 1c may be configured to pour or pressure inject a
distinct engineered mixture designed, for example, to be water
proof or with characteristics identical to those provided by the
engineered mixture 14 provided by reactor 1a. The thicknesses of
each layer may be adjusted by changing the pouring or pressure
injection rates of each distinct diffuser 9, 9a, or 9b with respect
to each other, thereby provide the means to manufacture a building
panel accurately engineered to meet selected specifications. In
this configuration positioning of one or more radiation sources 25
(as shown in FIG. 1) may allow curing of one or more selected
layers of engineered mixtures 14, 14a, or 14b.
[0043] In FIG. 6 a preferential high-performance building panel
manufacturing method is shown. In this embodiment the substantially
flat heated or cooled surface 17a is movable by means of a properly
designed endless belt for a high-rate continuous production line.
The features described in the various embodiments of FIG. 1 to FIG.
5 also apply to the preferential method of FIG. 6. The thickness of
layers of pre-shaped engineered mixtures 14, 14a, and 14b is
arbitrary. Radiation source 25 may also be positioned between
diffusers 9, 9a, and 9b so as to expose each distinct engineered
mixture to different or similar radiation intensities as required
for different applications.
[0044] In FIG. 7 the preferential high-performance building panel
manufacturing method described in FIG. 6 is further optimized by
means of a system 24 configured to control the pressure, e.g.,
about 35-40 psi, temperature, e.g., about 68.degree.-75.degree. F.,
and humidity, e.g., about 50-65% absolute humidity, of the
engineered mixture after it has been poured or pressure injected.
In this manner evaporation and curing time may be optimized while
assuring the highest quality and reliability of the final product.
In this FIG. 27c represents a pressurizer able to pressurize or
depressurize, e.g., in the range of about 20-40 psi the ambient
surrounding the building panel during manufacturing. A heating or
cooling system 27a is configured to maintain the temperature of the
environment surrounding the engineered mixture at desired values,
e.g., about 68.degree.-75.degree. F., while the engineered mixture
is being processed. System 27b represents a control mechanism
assuring that proper humidity is maintained during manufacturing.
Seals 24s may be made of flexible membranes assuring minimum fluid
leakage in or out of the controlled environment included within
system 24.
[0045] FIG. 8 is a top-view representation of one or multiple
layers of the engineered mixture after being poured or pressure
injected onto the substantially flat surface 17. In this Figure the
diffuser 9 positions a pre-shaped layer of a first engineered
mixture, one or more axially spaced diffuser(s) 9a position(s)
another pre-shaped layer of a second engineered mixture, and
diffuser 9b positions another pre-shaped layer of a third
engineered mixture. First, second and third engineered mixtures may
be distinct or the same. By changing the shape of diffuser 9a, for
example by reducing its pre-shaped engineered mixture outlet a
series of patterns may be created within the building panel. In
this manner a more rigid mixture may be formed in the central layer
of the building board, while more flexible engineered mixtures may
be used on the layers exposed to the environment.
[0046] FIG. 9 provides an example of a method utilized to shape the
surface exposed to the environment with an artificial wood grain or
other desired patterns. In this figure a roller 1 6b whose surface
has been three-dimensionally modified may be used to press the
building panel during the manufacturing process so as to obtain a
non-glossy surface. A similar result may be obtained by using a
pre-molded shape onto the substantially flat surface 17.
[0047] FIG. 10 indicates a multilayered building panel wherein the
inner layer 14a is formed by coated or uncoated micro-spheres 14d.
These micro-spheres have multiple purposes as they may be hollow so
as to decrease the building panel thermal conductivity, thereby
increasing the building panel insulation properties. The
micro-spheres may be filled with a fluid or a solid substance whose
contact with a flame may release fire retardant and fire
suppressant chemicals. The micro-spheres may be coated with a
substance 14e which makes the micro-sphere's material un-reactive
with the rest of the engineered mixture A, B, C, D and E shown in
FIG. 1. The micro-spheres may also be un-coated so as to favor
chemical reactions with the other chemical components forming the
engineered mixtures.
[0048] An example of a list of chemicals or components utilized to
prepare selected engineered mixtures (i.e. 14 in FIG. 1, or 14a,
14b in FIG. 5 and FIG. 6) according to the embodiments of this
invention are represented in FIG. 11 (Table 1). As shown in Table 1
the chemicals are mixed according to selected ratios and are
referenced to high-performance building panels of different
thicknesses (e.g., 11 mm or 6 mm) and dimensions (e.g., 2440 mm or
1525 mm length). The specific composition of each component may be
varied by up to .+-.5-10%. In both tables under the "Raw Material"
list, perlite powder and/or wood powder may be substituted with
industrial recycled glass or glass beads (which may be colored),
ceramic powder, light-radiation sensitive materials, and/or coated
or uncoated micro-spheres.
[0049] In one example the wall board composition includes a core
mix including two or more basic ingredients, such as MgO and
MgCl.sub.2, sometimes referred to as "mud", as well as one or more
fillers or binders (or substitutes) listed. The core mix may
comprise about 70-85% of the entire mixture, while the balance
(about 15-30%) includes the fillers, binders and/or substitutes. In
one example, the one or more binders may include glass beads and/or
an antimicrobial (e.g., Microban or Durban). The glass beads or the
antimicrobial/anti-fungal may comprise about 2-3% of the entire
composition, and they may be a substitute for wood powder.
[0050] In addition, the composition may be formulated without or
substantially without silica or Perlite. In particular, the Perlite
powder and/or Perlite (<1 mm) content can be set to less than
3%, between about 2-3%, or less than about 2%. The silica can be
set to be less than about 2%, or less than 1%, but preferably less
than about 0.05%, or preferably about 0%.
[0051] While the invention has been described in connection with
what is presently considered to be the most practical and preferred
embodiments, it is to be understood that the invention is not to be
limited to the disclosed embodiments, but on the contrary, is
intended to cover various modifications and equivalent arrangements
included within the spirit and scope of the invention.
* * * * *