U.S. patent application number 13/284873 was filed with the patent office on 2013-05-02 for ecologically sustainable structural panel.
The applicant listed for this patent is Alfredo Rodriguez. Invention is credited to Alfredo Rodriguez.
Application Number | 20130104473 13/284873 |
Document ID | / |
Family ID | 48170951 |
Filed Date | 2013-05-02 |
United States Patent
Application |
20130104473 |
Kind Code |
A1 |
Rodriguez; Alfredo |
May 2, 2013 |
Ecologically Sustainable Structural Panel
Abstract
An ecologically sustainable structural panel. The structural
panel comprises of a unique gage frame, expanding foam, and
ecologically sustainable exterior sheathing boards. The
ecologically sustainable structural panel is fireproof, water
proof, mold proof, asbestos free, impact resistant, moisture
resistant, and bacteria resistant. The ecologically sustainable
structural panel is also capable of withstanding winds of up to 150
miles per hour due to unique operative connections between male
junctions, female junctions, L-junctions, anchors, and the
utilization of pins instead of screws.
Inventors: |
Rodriguez; Alfredo; (Miami,
FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Rodriguez; Alfredo |
Miami |
FL |
US |
|
|
Family ID: |
48170951 |
Appl. No.: |
13/284873 |
Filed: |
October 29, 2011 |
Current U.S.
Class: |
52/220.1 ;
52/309.4; 52/426 |
Current CPC
Class: |
E04C 2/296 20130101;
E04C 2/384 20130101 |
Class at
Publication: |
52/220.1 ;
52/426; 52/309.4 |
International
Class: |
E04B 2/34 20060101
E04B002/34; E04C 2/20 20060101 E04C002/20; E04C 2/52 20060101
E04C002/52 |
Claims
1. An ecologically sustainable structural panel, comprising: at
least two exterior sheathing boards comprising of a mixture of
magnesium oxide and gypsum; a gage frame, the gage frame defines a
plurality of stud members, each stud member defines two ends, each
stud member further defines at least one junction at the end of the
stud member for structural reinforcement, each stud member further
defines a substantially U-shaped cross-section, the substantially
U-shaped cross-section has a small variance in width so that two of
the opposing stud members slide together to form a hollow and
substantially rectangular stud member, the hollow and substantially
rectangular stud member defines an opening along its longitudinal
axis suitable for injecting an amorphous material, and a plurality
of pins for structural reinforcement, whereby the stud members
connect to each other using the junctions and the pins; an
expandable foam comprising an amino resin, the amino resin
comprising phenol, urea, melamine, and aldehyde, the expandable
foam is inserted into the hollow and substantially rectangular stud
member; and a plurality of anchors for securing the gage frame to a
floor surface.
2. The ecologically sustainable structural panel of claim 1,
wherein the junctions are either male, female, or L-shaped.
3. The ecologically sustainable structural panel of claim 2,
wherein the gage frame is made of galvanized steel.
4. The ecologically sustainable structural panel of claim 3,
further comprise of at least one electrical pipe that embeds into
the gage frame for structural reinforcement.
5. The ecologically sustainable structural panel of claim 4,
wherein each electrical pipe is a half inch pvc pipe.
6. The ecologically sustainable structural panel of claim 5,
wherein the expandable foam is ecologically sustainable,
recyclable, water proof, fire proof, mold proof, does not contain
metals, and does not contain asbestos.
7. The ecologically sustainable structural panel of claim 6,
wherein the anchor dimensions are about five and an eighth by about
four inches.
Description
BACKGROUND
[0001] The inventor of the present invention has been in the
construction industry for 15 years and has a background in
engineering. During his period of working in the construction
industry he identified a problem with existing structural
panels.
[0002] One of the major problems with the structural panels
presently used is that they use Expanded Polystyrene (hereinafter
referred to as "EPS") materials during fabrications. EPS materials
are used to insulate the panels. However, EPS materials are toxic
and highly flammable. The present invention uses expandable foam
from the amino resin family, consisting of phenol, urea, and
melamine coupled with an aldehyde to obviate the toxicity normally
present in EPS when fabricating structural panels.
[0003] Another danger of using EPS material based structural panels
is that when they catch on fire, the EPS material structural makeup
collapses, thereby making any structure constructed using the
structural panels structurally deficient. The present invention
uses an amino resin foam material to insulate the structural
panels. This amino resin foam has a high melting point, is
resistance to moisture, and is resistance to bacteria. The amino
resin foam increases the structural makeup of structural panels
using this material.
[0004] The inventor first identified the toxic and structural
elements that were problematic in the structural panel industry in
2003 and worked diligently to find a solution to the problem. The
solution consisted of finding a material that would have a high
melting point and that at the same time would not be toxic upon
being ignited.
[0005] The inventor's research also lead him to discover that
structural panel sheathing boards could be fabricated from two
chief ingredients: magnesium oxide, which is a fireproofing
material, and gypsum, which provides good finishing qualities and
cementing characteristics for structural panels. The sheathing
boards were rigid enough to act as structural paneling and provided
the further advantage of being recyclable.
[0006] The above findings caused the inventor first to create
sheathing boards from magnesium oxide and gypsum. He then procured
expandable foam composed of amino furin resins. He then filled the
hollow space between two sheathing boards with the expandable foam
and finally used pins to attach the sheathing boards. This produced
an ecologically sustainable structural panel that was fire proof,
mold proof, moisture resistant, bacteria resistant, and free of
asbestos, and metals. However, the structural panel still lacked
the structural integrity to withstand strong winds and sudden
impacts.
[0007] The inventor further realized that the best way to achieve
structural integrity was to provide a frame for the structural
panel. He recalled that L-junctions were efficacious in providing
resistance to vertical forces such as hurricane strength winds. He
also knew that male and female junctions would reinforce each other
and provide the synergy to create a strong overall frame. After
trial and error, he created galvanized steel stud members having a
substantially U-shaped cross-section. The stud members slid into
each other to create a hollow rectangular stud member. The inventor
then connected the stud members into a frame by utilizing male
junctions, female junctions, L-junctions and pins. He then anchored
the frame to the floor surface with an industrial grade 5
1/8.times.4 inch anchor screw. The inventor next filled in the
hollow space between the rectangular stud member with the
expandable foam. Finally, he sandwiched the frame between two
sheathing boards to create his ecologically sustainable structural
panel.
[0008] Structural panels have been used in the construction
industry in the past, yet none with the present characteristics of
the present invention. See U.S. Pat. Nos.: 4,765,105; 4,578,909;
2008/0115442; 2009/0056255; and 3,797,190.
[0009] For the foregoing reasons, there is a need for an
ecologically sustainable structural panel that is fireproof, water
proof, mold proof, asbestos free, impact resistant, moisture
resistant, bacteria resistant, and that can withstand winds of up
to 150 miles per hour.
SUMMARY
[0010] The present invention is directed to an ecologically
sustainable structural panel that is fireproof, water proof, mold
proof, asbestos free, impact resistant, moisture resistant, and
bacteria resistant. The ecologically sustainable structural panel
is also capable of withstanding winds of up to 150 miles per hour
due to unique operative connections between male junctions, female
junctions, L-junctions, anchors, and the utilization of pins
instead of screws.
[0011] The present invention is an ecologically sustainable
structural panel. The structural integrity of the structural panel
comes from its unique gage frame and expanding foam. The gage frame
is composed of galvanized steel stud members designed to fit
together for maximum structural reinforcement. The stud members,
which have a U-shaped cross-section are constructed to slide into
each other, forming a hollow and substantially rectangular stud
member. Male junctions, female junctions, L-junctions, pins, and
anchors located at the ends of the stud members connect to form
secure connections. Electrical pvc pipes are also embedded into the
gage frame to increase structural integrity. Since the gage frame
is made of galvanized steel, it is fireproof. A unique expanding
foam composed of an amino resin fills a cavity located inside the
hollow and substantially rectangular stud member and provides
desirable properties for the structural panel such as
recyclability, fire resistance, mold resistance, impact resistant,
moisture resistance, and bacteria resistance. Exterior sheathing
boards composed chiefly of gypsum and magnesium oxide sandwich the
gage frame to form the complete structural panel. The sheathing
boards are also recyclable, fire proof, mold proof, impact
resistant, moisture resistant, bacteria resistant, and do not
contain metals, or asbestos. Furthermore, the complete structural
panel is prefabricated; prefabrication reduces the time normally
spent installing structural panels.
[0012] An object of the present invention is to provide a
structural panel that is fireproof, water proof, mold proof,
asbestos free, impact resistant, moisture resistant, bacteria
resistant, and that can withstand winds of up to 150 miles per
hour.
[0013] Another object of the present invention is to reduce
construction costs by providing a prefabricated structural panel,
and using pins instead of screws for operative connectivity.
[0014] Yet another object of the present invention is to provide a
ecologically sustainable, recyclable structural panel free of
organic solvents, oils, and toxins.
DRAWINGS
[0015] These and other features, aspects, and advantages of the
present invention will become better understood with regard to the
following description, appended claims, and drawings where:
[0016] FIG. 1 is a side view of the present invention;
[0017] FIG. 2 is a cross-sectional view of the present invention;
and
[0018] FIG. 3 is a frontal view of the present invention.
DESCRIPTION
[0019] One embodiment of the ecologically sustainable structural
panel 200 is seen in FIGS. 1-3. The ecologically sustainable
structural panel 200 is used to provide structural paneling that is
fireproof, water proof, mold proof, asbestos free, moisture
resistant, and bacteria resistant. The ecologically sustainable
structural panel 200 is also capable of withstanding winds of up to
150 miles per hour due to its unique use of junctions and
fittings.
[0020] The ecologically sustainable structural panel 200 comprises
of at least two exterior sheathing boards 10 comprised of a mixture
of magnesium oxide and gypsum, whereby a rigid surface will be
provided. The ecologically sustainable structural panel 200 also
comprises of a gage frame 20 for providing structural integrity.
The gage frame 20 comprises of a plurality of stud members 30. Each
stud member 30 defines at least one end 35. Each stud member 30
further defines at least one junction 37 at the ends 35 of the stud
member for structural reinforcement. The stud member 30 ends 35
utilize either a male junction 70 for structural reinforcement, a
female junction 80 for structural reinforcement, or an L-junction
90 for structural reinforcement, whereby the stud members 30
connect to each other using the male junctions 70, the female
junctions 80, and the L-junctions 90 located at their two ends 35,
along with a plurality of pins 100. Each stud member 30 further
defines a substantially U-shaped cross-section 40. Each U-shaped
cross-section 40 defines a small variance in width so that when two
opposing stud members 30 slide together, they form a hollow and
substantially rectangular stud member 50. Each hollow and
substantially rectangular stud member 50 defines an opening 60
along its longitudinal axis suitable for injecting an amorphous
material inside a cavity in the opening 60 of the hollow and
substantially rectangular stud member 50. The ecologically
sustainable structural panel 200 further comprises of an expandable
foam 110 composed of an amino resin, the amino resin comprises of
phenol, urea, melamine, and aldehyde. The expandable foam 110 fills
the cavity inside the opening 60 of the hollow and substantially
rectangular stud member 50. The ecologically sustainable structural
panel 200 further comprises of a plurality of anchors 120 for
securing the gage frame 20 to a floor surface 130. After the
expandable foam 110 fills the cavity in the hollow and
substantially rectangular stud member 50, the exterior sheathing
boards 10 sandwich the gage frame 20 to form a completed
ecologically sustainable structural panel 200.
[0021] In an embodiment of the present invention, the gage frame 20
is made of galvanized steel.
[0022] In a further embodiment of the present invention, half inch
electrical pvc pipes are embedded into the gage frame 20 for
structural reinforcement.
[0023] In yet another embodiment of the present invention, the
expandable foam 110 is water proof, fire proof, mold proof, does
not contain metals, or asbestos.
[0024] An advantage of the present invention is that the exterior
sheathing boards 10 are ecologically sustainable, recyclable, and
contain no organic solvents, oils, or toxins.
[0025] Another advantage of the present invention is that it is
prefabricated and ready to install on site, whereby construction
costs are reduced by at least 30%.
[0026] Another advantage of the present invention is that it
comprises of an expandable foam 110 that is water proof, fire
proof, mold proof, and does not contain metals, or asbestos.
[0027] Yet another advantage of the present invention is that the
ends of the stud members 30 are held down by pins 100 rather than
screws, whereby construction time and costs are significantly
reduced.
[0028] Yet another advantage of the present invention is that the
gage frame 20 is made of galvanized steel rather than wood, whereby
the risk of fire is eliminated.
[0029] Yet another advantage of the present invention is that it is
Florida hurricane tested, STC-Rated 53-54, and ready for all 2007
ICC criteria.
[0030] Although the present invention has been described in
considerable detail in reference to preferred versions, other
versions are possible. Therefore, the spirit and scope of the
appended claims should not be limited to the description of the
preferred versions contained herein.
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