U.S. patent application number 13/972748 was filed with the patent office on 2015-02-26 for laminate building materials and methods of making and installing the same.
This patent application is currently assigned to MagBoard, LLC. The applicant listed for this patent is MagBoard, LLC. Invention is credited to Humberto F. Hassey, Gordon D. Ritchie.
Application Number | 20150052838 13/972748 |
Document ID | / |
Family ID | 52479108 |
Filed Date | 2015-02-26 |
United States Patent
Application |
20150052838 |
Kind Code |
A1 |
Ritchie; Gordon D. ; et
al. |
February 26, 2015 |
LAMINATE BUILDING MATERIALS AND METHODS OF MAKING AND INSTALLING
THE SAME
Abstract
Magnesium oxide cement sheathing is laminated to plywood, OSB,
wood, steel, other building products or other substrates to enhance
fire, structural and sound performance of the substrate to meet new
and more stringent fire codes while also providing water, insect,
mold and rot protection. Further, the magnesium oxide cement board
laminated to a foam core enhances fire performance and mold and rot
protection over that of the foam core alone. The magnesium oxide
laminate is used in wall, floor and roof assemblies to meet or
exceed performance as specified in the building codes.
Inventors: |
Ritchie; Gordon D.;
(Edmonton, CA) ; Hassey; Humberto F.; (Coronado,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MagBoard, LLC |
Reno |
NV |
US |
|
|
Assignee: |
MagBoard, LLC
Reno
NV
|
Family ID: |
52479108 |
Appl. No.: |
13/972748 |
Filed: |
August 21, 2013 |
Current U.S.
Class: |
52/408 ;
156/331.7; 156/332; 156/336; 156/60 |
Current CPC
Class: |
B32B 27/306 20130101;
B32B 2266/0278 20130101; B32B 27/065 20130101; B32B 2307/3065
20130101; E04C 3/29 20130101; B32B 21/08 20130101; B32B 2266/0207
20130101; B32B 2419/00 20130101; B32B 2307/7265 20130101; B32B
27/40 20130101; B32B 5/18 20130101; B32B 2266/0228 20130101; B32B
13/02 20130101; B32B 2266/0235 20130101; B32B 2266/0264 20130101;
Y10T 156/10 20150115; B32B 2307/7145 20130101; B32B 21/02 20130101;
B32B 13/10 20130101; B32B 2266/06 20130101; B32B 2307/558 20130101;
B32B 13/045 20130101; B32B 13/12 20130101; B32B 2266/08 20130101;
B32B 7/12 20130101; B32B 2262/101 20130101 |
Class at
Publication: |
52/408 ; 156/60;
156/332; 156/336; 156/331.7 |
International
Class: |
E04C 3/29 20060101
E04C003/29 |
Claims
1. A building material comprising: a magnesium oxide (MgO) board; a
substrate; and an adhesive layer interposed between the MgO board
and the substrate, the MgO board laminated to the substrate with
the adhesive layer to form a laminate.
2. The building material of claim 1 wherein the laminate comprises
a flame spread rating of about zero according to ASTM E-84.
3. The building material of claim 1 wherein the laminate comprises
a smoke generation rating of about zero according to ASTM E-84.
4. The building material of claim 1 wherein the laminate is
noncombustible according to ASTM E-136.
5. The building material of claim 1 further comprising a finishing
material directly applied to the laminate without additional fire
or moisture protection.
6. The building material of claim 1 wherein the substrate comprises
an oriented strand board (OSB).
7. The building material of claim 6 wherein the laminate comprises
at least one of a greater resistance to fungal growth than the OSB,
a greater structural strength than the OSB, and a greater
resistance to moisture than the OSB.
8. The building material of claim 1 wherein the substrate comprises
a foam core material.
9. The building material of claim 1 wherein the adhesive layer is
selected from the group consisting of polyvinyl acetate (PVA),
water-based polymeric adhesives, solvent-based adhesives,
thermostat adhesives, modified starches, liquid moisture cure
adhesives, and polyurethane.
10. The building material of claim 1 wherein the adhesive layer is
associated with a permeability and the laminate comprises a
structural vapor diffusion retarder.
11. The building material of claim 1 wherein the substrate
comprises a joist including an upper flange, a lower flange, and a
web interposed between the upper and the lower flanges.
12. The building material of claim 11 wherein the MgO board is
laminated to at least one side of the web.
13. The building material of claim 11 wherein the MgO board is
laminated to both sides of the web.
14. The building material of claim 11 wherein the MgO board is
laminated to the upper flange and the lower flange along the length
of the joist.
15. The building material of claim 11 wherein the MgO board encases
the joist.
16. The building material of claim 1 wherein the MgO board forms at
least one surface of a laminate to increase the fire rating of a
wall assembly.
17. A method to fabricate a building material, the method
comprising: providing a magnesium oxide (MgO) board; providing a
substrate; and interposing an adhesive layer between the MgO board
and the substrate to laminate the MgO board to the substrate with
the adhesive layer to form a laminate.
18. The method of claim 17 wherein the laminate comprises a flame
spread rating of about zero according to ASTM E-84.
19. The method of claim 17 wherein the laminate comprises a smoke
generation rating of about zero according to ASTM E-84.
20. The method of claim 17 wherein the laminate is noncombustible
according to ASTM E-136.
21. The method of claim 17 further comprising a finishing material
directly applied to the laminate without additional fire or
moisture protection.
22. The method of claim 17 wherein the substrate comprises an
oriented strand board (OSB).
23. The method of claim 22 wherein the laminate comprises at least
one of a greater resistance to fungal growth than the OSB, a
greater structural strength than the OSB, and a greater resistance
to moisture than the OSB.
24. The method of claim 17 wherein the substrate comprises a foam
core material.
25. The method of claim 17 wherein the adhesive layer is selected
from the group consisting of polyvinyl acetate (PVA), water-based
polymeric adhesives, solvent-based adhesives, thermostat adhesives,
modified starches, liquid moisture cure adhesives, and
polyurethane.
26. The method of claim 17 wherein the substrate comprises a joist
including an upper flange, a lower flange, and a web interposed
between the upper and the lower flanges.
27. The method of claim 26 wherein the MgO board is laminated to at
least one side of the web.
28. The method of claim 26 wherein the MgO board is laminated to
both sides of the web.
29. The method of claim 26 wherein the MgO board is laminated to
the upper flange and the lower flange along the length of the
joist.
30. The method of claim 26 wherein the MgO board encases the joist.
Description
INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS
[0001] Any and all applications for which a foreign or domestic
priority claim is identified in the Application Data Sheet as filed
with the present application are hereby incorporated by reference
under 37 CFR 1.57.
BACKGROUND
[0002] Building departments in the US recognize that increased
urban density elevates the risk of fire spreading to adjacent
buildings. In addition, increased development has led to the
construction of many buildings in wildfire-urban interface zones.
The result is stronger mandates for fire codes that require the use
of non-combustible and fire rated materials in new and retrofit
construction. Requirements focus on exterior walls, roofs, and
floor structures in various construction applications.
[0003] Fire codes focus on flame spread, smoke generation, and
duration of material performance during a fire. The codes determine
materials performance requirements as well as wall assembly
requirements necessary to meet several classes of construction.
Typical wood framed walls and roofs utilize plywood or oriented
strand board (OSB) as the exterior sheathing or roofing material.
In many applications, codes require structure exteriors that are
non-combustible.
[0004] One response to the fire codes has been to coat wood based
sheathing with an intumescent substance that increases fire
performance. Another has been to introduce fire resistant additives
in the manufacture of OSB or plywood. Neither of these approached
work very well.
[0005] Builders sometimes use fire resistant materials, such as
gypsum based sheathing, cementatious siding, and a sufficient
thickness of stucco, brick, or stone veneer, in wall and roof
assemblies where performance is specified in the building codes.
Such materials are not structural so they are added in addition to
structural sheathing which now must also be protected from water
penetration behind the fire barrier. These are layered, costly, and
time consuming assemblies.
SUMMARY
[0006] Embodiments describe the lamination of Magnesium Oxide (MgO)
cement based boards or sheathing to building materials. In an
embodiment, the MgO cement boards are structural and comprise
fiberglass-reinforced magnesium oxide cement boards.
Boards/sheathing made with MgO cement are noncombustible and
generate no smoke when exposed to flame. Unlike OSB, MgO cement
boards or sheathing do not support mold or mildew, are
insect-proof, and are water, freeze/thaw, and impact resistant. The
MgO cement boards have low thermal conductivity, reflect heat
radiation and help isolate the wood and other building materials
from the heat source.
[0007] They can be laminated to wood-based and other products to
substantially improve fire performance. Further, the MgO laminate
improves the mold and rot protection of the substrate, and
eliminates many of the steps required to protect wood or other
substrate, which, in turn, reduces building costs. By modifying the
chemical mixture, ingredients, and thickness, MgO cement boards can
also be engineered to increase the structural performance of an MgO
laminated board. The MgO laminate is an ideal solution since the
OSB or plywood is already approved for structural performance under
the prescriptive building codes and the MgO provides the fire
performance required to meet new codes.
[0008] In another embodiment, the MgO cement boards can be
laminated to foam materials to substantially improve fire, water,
rot, and mold performance. In addition, by using MgO laminated
products, many other building products can be manufactured with the
added performance the MgO provides.
[0009] Certain embodiments disclose a building material. The
building material comprises a magnesium oxide (MgO) board, a
substrate, and an adhesive layer interposed, applied, or located
between the MgO board and the substrate, where the MgO board is
laminated to the substrate with the adhesive layer to form a
laminate. In an embodiment, the laminate comprises a flame spread
rating of about zero according to ASTM E-84. In another embodiment,
the laminate comprises a smoke generation rating of about zero
according to ASTM E-84. In another embodiment, the laminate has an
airborne sound reduction index of 31 db according to testing done
by the China Building Materials Center for Quality Supervision. In
a further embodiment, the laminate is noncombustible according to
ASTM E-136. In a yet further embodiment, the building material
further comprises a finishing material directly applied to the
laminate without additional fire or moisture protection, where the
finishing material comprises stucco, siding, brick, decorative
stone, molding and the like.
[0010] In an embodiment, the substrate comprises an oriented strand
board (OSB), where the laminate comprises a greater resistance to
fungal growth than the OSB, a greater structural strength than the
OSB, a greater resistance to moisture than the OSB. In another
embodiment, the substrate comprises a foam core material. In a
further embodiment, the adhesive layer is selected from the group
consisting of polyvinyl acetate (PVA), water-based polymeric
adhesives, solvent-based adhesives, thermostat adhesives, modified
starches, liquid moisture cure adhesives, and polyurethane.
[0011] In an embodiment, the substrate comprises a wooden joist
including an upper flange, a lower flange, and a web interposed
between the upper and the lower flanges. In another embodiment, the
MgO board is laminated to at least one side of the web. In a
further embodiment, the MgO board is laminated to both sides of the
web. In a yet further embodiment, the MgO board encases the wooden
joist. In an embodiment, the MgO board is laminated to the upper
flange and the lower flange along the length of the joist. In
another embodiment, the joist is a floor and roofing I-joist.
[0012] According to some embodiments, a method to fabricate a
building material is disclosed. The method comprises providing a
magnesium oxide (MgO) board, providing a substrate, and interposing
an adhesive layer between the MgO board and the substrate to
laminate the MgO board to the substrate with the adhesive layer to
form a laminate.
[0013] For purposes of summarizing the disclosure, certain aspects,
advantages and novel features of the inventions have been described
herein. It is to be understood that not necessarily all such
advantages may be achieved in accordance with any particular
embodiment of the invention. Thus, the invention may be embodied or
carried out in a manner that achieves or optimizes one advantage or
group of advantages as taught herein without necessarily achieving
other advantages as may be taught or suggested herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1A illustrates a perspective view, partially cut away,
of a laminated panel, according to certain embodiments.
[0015] FIG. 1B illustrates a cross-sectional view of the laminated
panel of FIG. 1A, according to certain embodiments.
[0016] FIG. 2 is a flow chart illustrating a process to manufacture
a laminated building material, according to certain
embodiments.
[0017] FIG. 3 illustrates a typical wooden joist, according to
certain embodiments.
[0018] FIG. 4 illustrates a typical wooden I-joist, according to
certain embodiments.
[0019] FIG. 5 illustrates a laminated fire resistant joist,
according to certain embodiments.
[0020] FIG. 6 illustrates a laminated fire resistant I-joist,
according to certain embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] The features of the systems and methods will now be
described with reference to the drawings summarized above.
Throughout the drawings, reference numbers are re-used to indicate
correspondence between referenced elements. The drawings,
associated descriptions, and specific implementation are provided
to illustrate embodiments of the inventions and not to limit the
scope of the disclosure.
[0022] FIG. 1A illustrates a perspective view, partially cut away,
of a laminated panel or laminate 100. The laminated panel 100
comprises a first layer 102 and a second layer or substrate 104.
FIG. 1B illustrates a cross-sectional view of the laminate 100 and
shows the first layer 102 and the second layer 104 may be laminated
together using an adhesive 106 to create a single piece laminate
composite. The laminate 100 can take any form necessary, including,
but not limited to panels, sheets, skins, boards, or the like.
[0023] The substrate 104 comprises any of a plurality of building
materials, such as, for example, OSB, plywood, wood, steel, metal,
foam, foam cores, gypsum based sheathing, and the like. Examples of
foam and/or foam cores are polyurethane, polyester, closed cell
polyester, extruded polystyrene, ester, latex rubber, neoprene,
vinyl, closed cell sponge rubber, open cell sponge rubber,
cellulose, polystyrene, polyvinylchloride PVC.
[0024] In an embodiment, the adhesive 106 comprises a water-based
polymeric adhesive, such as a latex-based adhesive, or the like.
Other examples of the adhesive 106 are, but not limited to,
polyvinyl acetate (PVA), solvent-based adhesives, thermostat
adhesives, natural polymers such as modified starches, liquid
moisture cure or reactive hot melt adhesives such as polyurethane,
heat or fire resistant adhesives, and the like.
[0025] In an embodiment, the first layer 102 comprises Magnesium
Oxide (MgO) cement based boards or sheathing. In another
embodiment, the MgO cement boards 102 are structural and comprise
fiberglass-reinforced MgO cement boards. In a further embodiment,
the layer 102 comprises MagBoard.TM., the properties of which are
described below in Tables A-D. All testing was done in accordance
to the International Accreditation Service (IAS) ISO
Guidelines.
[0026] In an embodiment, the thickness of the MgO laminate 100
ranges from approximately 9 mm to approximately 42 mm and
preferably from approximately 12 mm to approximately 24 mm. In an
embodiment, the thickness of the first layer 102 ranges from
approximately 3 mm to approximately 18 mm and preferably from
approximately 6 mm to approximately 12 mm. In an embodiment, the
thickness of the substrate 104 ranges from approximately 3 mm to
approximately 24 mm, more preferably from approximately 6 mm to
approximately 18 mm.
[0027] Another example of an MgO laminated building product 100 is
the MgO/foam laminate 100 which can be used in the construction of
recreational vehicles (RVs), such as for interior and exterior wall
partitions. Typically the RV industry uses a 3 mm wood based
plywood product laminated to extruded polystyrene (XPS) foam, which
does not perform well in fires, rots easily, and supports mold.
Replacing the wood based substrate with the MgO/foam laminate 100
enhances the long term performance of the wall partitions and
provides enhanced fire, rot, mold, sound and insect resistance over
that of the foam alone.
[0028] In an embodiment, the MgO/foam laminate comprises MgO cement
based sheathing 102 laminated to a foam core substrate 104. In an
embodiment, MgO sheathing 102 is laminated to the foam core 104
using the adhesive 106. In some embodiments, the MgO cement based
sheathing 102 comprises MagBoard.TM. and the foam core 104
comprises extruded polystyrene foam. In a preferred embodiment, the
MgO/foam laminate 100 comprises an approximately 3 mm thick sheet
of MagBoard.TM. laminated to approximately one inch of extruded
polystyrene foam. In other embodiments, the MgO board 102 can be
more or less than 3 mm, the substrate 104 can be more or less than
one inch, and the substrate 104 can comprise one or more of
polyurethane, polyester, closed cell polyester, ester, latex
rubber, neoprene, vinyl, closed cell sponge rubber, open cell
sponge rubber, cellulose, polystyrene, polyvinylchloride PVC, and
the like.
Tests and Test Results
[0029] Table A provides the test and performance requirements, the
test standards, the requirements, and the test results for physical
property testing of approximately 12 mm or 1/2 inch thick
MagBoard.TM..
TABLE-US-00001 TABLE A PHYSICAL PROPERTIES TESTING (12 mm 1/2 inch)
TEST AND PERFORMANCE REQUIREMENTS TEST STANDARD REQUIREMENTS TEST
RESULTS Non ASTM E136-09a No flaming under test Rated as Non
Combustible Combustible parameters Surface Burning ASTM E84 5 smoke
10 flame 0 smoke 0 flame Characteristics contribution contribution
Flexural Strength ICC-ES AC386 min 580 psi both dry parallel 1576
psi ASTM C1185-08 wet and dry dry perpendicular 2,251 psi wet
parallel 1,291 psi, wet perpendicular 2,041 psi Freeze Thaw ASTM
C666 No disintegration after Pass Cycling 25 Cycles Dimension And
ASTM C1186 Pass Tolerance Moisture ICC-ES AC386 Accepted
dimensional 0.02%, Movement ASTM C1185-08: tolerance from 30 to 90%
humidity Water ICC-ES AC386 29.80% Absorption ASTM C1185-08 Water
Vapor ASTM E96/E96M-05 2.46 perms Transmission Compression ICC-ES
AC386 >1250 psi <.05 inch Pass 1736 PSI Indentation ASTM
D2394 Nail Head Pull ICC-ES AC386 >90 lb. 292 lb-pass Through
ASTM D1037-99: Lateral Nail ICC-ES AC378 >90 lb. Pass Resistance
ASTM D1037-99: 1/4'' dry 115 lb, wet 41 lb 3/8'' dry 196 lb, wet
113 lb, 1/2'' dry 261 lb, wet 157 lb, 3/4'' dry 337 lb, wet 209 lb
Falling Ball ICC-ES AC386 no damage at 12'' drop Pass Impact ASTM
D1037-99:
[0030] Table B provides the test and performance requirements, the
test standards, the requirements, and the test results for assembly
and panel structural testing of approximately 12 mm or 1/2 inch
thick MagBoard.
TABLE-US-00002 TABLE B ASSEMBLY and PANEL STRUCTURAL TESTING (12 mm
1/2 inch) TEST AND PERFORMANCE REQUIREMENTS TEST STANDARD
REQUIREMENTS TEST RESULTS Structural ASTM E72-05 Transverse Load
Positive pressure 260 psf 2 .times. 6 WoodFrame (Assembly exceeded
test recorded frame capabilities) Negative Pressure 210.7 psf Wet
Racking Shear 5270 lbs 658.8 plf 1/8 in deflection 1483 lbs 185.4
plf Structural ASTM E72-05 Transverse Load, Positive pressure 237
psf 2 .times. 4 SteelFrame Wet Racking Shear Negative Pressure 102
psf 7494 lbs 936.67 plf Structural ASTM E72-02 Ultimate Transverse
0 161 psf Insulated panel ASTME564 bearing 4 ft .times. 8 ft
.times. 6.5 inch Allowable Transverse 0 44.8 psf bearing Ultimate
Transverse bearing 178.5 psf Allowable Transverse 59.5 psf bearing
Ultimate Axial load 55,741 lbs Allowable Axial load 4645 lbs
Ultimate Shear 10,869 lbs Allowable Shear 453 plf Structural ASTM
E72-02 Ultimate Transverse 0 185.7 psf Insulated Panel ASTM E564
bearing 4 ft .times. 8 ft .times. 8.5 inch Allowable Transverse 0
61.9 psf bearing Ultimate Transverse bearing 182.6 psf Allowable
transverse bearing 65.7 psf Ultimate Axial load 66,246 lbs
Allowable Axial load 5,521 lbs Ultimate Shear 10,063 lbs Allowable
Shear 377 plf Structural ASTM E72-02 Ultimate Transverse 182 psf
Insulated Panel ASTM E564 Axial load 43,247 lbs 4 ft .times. 9 ft
.times. 6.5 inch Structural ASTM E72-02 Ultimate Transverse 224 psf
Insulated Panel ASTM E564 Axial load 51,888 lbs 4 ft .times. 9 ft
.times. 8.25 inch
[0031] Table C provides the test and performance requirements, the
test standards, the requirements, and the test results for assembly
and panel fire testing of approximately 12 mm or 1/2 inch thick
MagBoard.
TABLE-US-00003 TABLE C ASSEMBLY and PANEL FIRE TESTING (12 mm 1/2
inch) TEST AND PERFORMANCE TEST TEST REQUIREMENTS STANDARD
REQUIREMENTS RESULTS Fire Rated E119-08a Per assembly* 2 Hour Fire
Assembly Endurance 2 .times. 6 Wood Frame Rating Fire Rated
E119-08a Per assembly* 2 Hour Fire Assembly Endurance 2 .times. 4
Steel Frame Rating 6.5 inch Structural E84-10b Per assembly 0 Flame
spread Insulated Panel 0 Smoke generation 6.5 inch Structural
E119-10a Per assembly* 2 hour fire Insulated Panel endurance
rating
[0032] Table D provides the test and performance requirements, the
test standards, the requirements, and the test results of wet area
underlayment and backer board testing of 6 mm or 1/4 inch thick
MagBoard.
TABLE-US-00004 TABLE D WET AREA UNDERLAYMENT AND BACKER BOARD TESTS
(6 mm 1/4 inch) TEST AND PERFORMANCE REQUIREMENTS TEST STANDARD
REQUIREMENTS TEST RESULTS Dimensional ASTM C1185 Length (in.) =/-
.25 Pass Tolerances Width (in.) =/- .25 Pass Thickness (in.) =/-
.25 Pass Square Straightness (in.) =/- .25 Pass Edge Straightness
(in.) =/- .25 Pass Flexural Strength ASTM C1185 >1450 PSI 2,854
psi Fastener Pull ASTM D1037 >.90 Pass Through Compressive ASTM
C1325 >1250 PSI Pass Strength ASTM D3295 Surface Burning ASTM
E84 5 smoke 10 flame 0 smoke 0 flame Characteristics contribution
contribution Non Combustible ASTM E136-09a No flaming under test
Rated as Non Combustible parameters Mold and Mildew ASTM G21 Non
Nutrient Pass Non Nutrient ASTM D3273 Fungus Testing ASTM D3273
Pass No evidence of fungal growth ASTM rating of 10 Linear
Variation ASTM D1037 Less than or equal to .07% 0.07% With Change
In Moisture Content Moisture ASTM C1185 Less than or equal to .02%
0.07% Movement % Linear Change Modulus of ASTM D1037 398,900 psi
456,100 psi Elasticity ANSI 208.1-99 Modulus of ASTM D1037 2,393
psi 3,071 psi Rupture ANSI 208.1-99 Modulus of ASTM D1037 retain
min of 50% MOR Pass Rupture Retention ANSI 208.1-99 Weight ASTM
1037 Weight per Sq. Ft. 1.4 lbs. Thickness Swell ASTM 1037 24 hour
thickness swell 3.5%-4% 7 day Shear Bond ANSI A 118.1 50 PSI at 7
day curing 98 psi Strength Portland Cement 7 Day Shear Bond ANSI
136.1 50 PSI at 7 day curing 189 psi Strength Organic Mortar Latex
Portland ANSI A 118.4 50 PSI at 7 day curing 201 psi Cement Mortar
Organic Mortar ANSI 136.1 50 PSI at 7 day curing Pass Humidified
ICC-ES AC386 <.3125 in. (ceiling) .053 in. Deflection ICC-ES
AC378 ASTM C473-07:
[0033] Table E provides the test and performance requirements, the
test standards, the requirements, and the test results of sound
testing of 12 mm or 1/2 inch thick MagBoard.TM. according to
testing done by the China Building Materials Center for Quality
Supervision.
Fire and Combustibility Testing
[0034] Of particular note are the results of the fire performance
testing. When evaluating building materials for fire safety, many
factors including ignition temperature, smoke toxicity and
flame-spread are considered. Flame-and smoke spread and
combustibility, used to describe the surface burning
characteristics of building materials, are among the most tested
fire performance properties of a material. The best known test for
developing a flame and smoke spread rating is the American Society
for Testing and Materials (ASTM) Test Method E-84, commonly known
as the tunnel test. The tunnel test measures how far and how fast
flames spread across the surface of the test sample. In this test,
a sample of the material 20 inches wide and 25 feet long, is
installed as ceiling of a test chamber, and exposed to a gas flame
at one end. The resulting flame spread rating (FSR) is expressed as
a number on a continuous scale where inorganic reinforced cement
board is 0 and red oak is 100. The scale is divided into three
classes. The most commonly used flame-spread classifications are:
Class I or A, with a 0-25 FSR; Class II or B with a 26-75 FSR; and
Class III or C with a 76-200 FSR.
[0035] Table A includes the ASTM E-84 test results for 12 mm
MagBoard.TM.; Table C includes the ASTM E-84 test results for a 6.5
inch Structural Insulated Panel of 12 mm MagBoard.TM.; and Table D
includes ASTM E-84 test results for 6 mm MagBoard.TM.. In each
case, MagBoard.TM. has a flame spread rating of approximately zero,
has a smoke generation rating of approximately zero, and is a Class
A material.
[0036] In contrast, OSB has a flame spread rating of approximately
148 and a smoke generation rating of approximately 137, and is a
Class C material. Since the ASTM E-84 test is a surface burning
test, the laminate 100 would have the same or similar test results
as the MagBoard test results. Thus, the MgO/OSB laminate 100 has
significantly improved surface burning and smoke generation
characteristics to that of the OSB substrate 104.
[0037] The best known test for combustibility is the American
Society for Testing and Materials (ASTM) Test Method E-136. The
ASTM E-136 test measures the behavior of materials in a vertical
tube furnace at 750.degree. C. Table D includes the ASTM E-136-09a
test results for 6 mm MagBoard. The test results indicate no
flaming under the test parameters and the MagBoard is rated as
non-combustible.
[0038] In contrast, OSB is combustible. Even with cementatious or
other fire retardant coatings, OSB is not rated as non-combustible.
Thus, the MgO/OSB laminate 100 has significantly improved
non-combustibility characteristics to that of the OSB substrate
104.
[0039] The ASTM E-119 test measures the hourly fire resistance
rating for an assembly using construction materials. An hourly fire
rating is the time a wall assembly can be expected to contain a
fire and, in the case of load-bearing walls, continue to provide
some structural support. This test is not a requirement for a
material to be used in non-combustible construction, but can be a
requirement based on the construction and occupancy types for the
building. Table C includes the ASTM E-119-08a test results for a
2.times.6 wood frame assembly constructed with approximately 12 mm
MagBoard and a 2.times.4 steel frame assembly constructed with
approximately 12 mm MagBoard. Table C further includes the ASTM
E-119-10a test results for a 6.5 inch structural insulated panel
(SIP) constructed with approximately 12 mm MagBoard. In each test,
the MagBoard assembly achieved at least a 2 hour fire endurance
rating.
[0040] In contrast, a partition wall assembly constructed with 15
mm OSB has a fire rating of approximately 14 minutes. Thus, the
MgO/OSB laminate 100 has significantly improved fire rating
characteristics to that of the OSB substrate 104.
[0041] Thus, by laminating Magboard 102 to a substrate 104, the
fire performance of a wall assembly can be greatly improved.
Further, by varying the thickness of the Magboard layer 102, the
laminate 100 can be manufactured to have a range of fire
performances, including flame spread, combustibility, and fire
rating, to meet current and future building codes. Building
products and or assemblies laminated with the MgO layer 102 can be
manufactured to have a range of fire performances, including flame
spread, combustibility, and fire rating, to meet current and future
building codes.
Mold/Rot Testing
[0042] ASTM D3273 tests for the resistance to growth of mold on the
surface interior coatings in an environmental chamber and ASTM G21
determines the effect of fungi on the properties of the tested
material. As indicated in Table D, MagBoard is a non-nutrient for
mold and mildew according to ASTM G21 and ASTM D3272 testing.
Further, there is no evidence of fungal growth according ASTM D3273
testing. MagBoard has an ASTM D3273 rating of 10, indicating no
disfigurement by particulate matter.
[0043] In contrast, structural wood products, such as OSB, lumber,
plywood, and the like, share the same basic chemical composition,
namely a matrix of cellulose and lignin, which support fungi, mold
and mildew growth. Often antifungal agents are applied to OSB to
reduce the risk of toxic mold growth. Further, during construction
of buildings, additional layers are added to protect OSB and other
wood products from moisture, a major cause of mold growth. This
adds additional construction costs.
[0044] The MgO board layer 102 provides fungi, mold, and mildew
resistance which is the same as or similar to the MagBoard ASTM G21
and D3273 test results to the laminate 100. Thus, the MgO/OSB
laminate 100 has significantly improved fungi, mold, and mildew
resistance characteristics to those of the OSB substrate 104
alone.
Structural Testing
[0045] ASTM E72-05 tests the strength of panels for building
construction. Table B indicates the ASTM E72-05 test results for
assemblies and panels comprising 12 mm MagBoard. The MagBoard
assembly and panel test results are consistent with the ASTM E72-05
test results for OBS, SIPs, or other building material assemblies
and panels.
Sound Testing
[0046] The Airborne Sound Reduction Index is used to measure the
level of sound insulation provided by a structure such as a wall,
window, door, or ventilator. This is a laboratory measurement,
which uses knowledge of the relative sizes of the rooms in the test
suite, and the reverberation time in the receiving room, and the
known level of noise which can pass between the rooms in the suite
by other routes (flanking) plus the size of the test sample to
produce a very accurate and repeatable measurement of the
performance of the sampled material or construction. Table E
indicates the Airborne Sound Reduction Index for 12 mm Magboard.TM.
is approximately 31 dB. Thus by laminating Magboard.TM. to the
substrate 104, an improvement in the sound performance of wall
assemblies can be achieved.
Vapor Retardant
[0047] Moisture or water vapor can move into building cavities in
three ways: with air currents; by diffusion through materials; and
by heat transfer. Of these three, air movement typically accounts
for more than 98% of all water vapor movement in building cavities.
Material that slow the rate of vapor diffusion into the thermal
envelope of a structure, such as the wall, ceiling, and floor
assemblies of buildings are referred to as vapor retarders. Vapor
retarders have varying degrees of permeability and have a moisture
vapor transmission rate that is established by standard test
methods. Permeability can be reported in perms, a measure of the
rate of transfer of water vapor through a material where 1.0 US
perm=1.0 grain/square-foot.cndot.hour.cndot.inch of mercury
.apprxeq.57 SI perm=57 ng/s.cndot.m2.cndot.Pa.
[0048] Adhesives act as vapor retarders and each adhesive has a
different vapor retardant property. In certain embodiments, the
adhesive 106 in the laminate 100 is a vapor retarder. The laminate
100 comprising the adhesive 106 comprises a structural vapor
diffusion retarder, which retards the diffusion of water vapor or
other moisture through wall, ceilings and floor assemblies of
buildings, as well as having other structural and fire resistant
properties. [0049] Building codes change often, and typically
become stricter to enhance safety and performance of the building
project. Advantageously, the MgO laminate 100 can meet or out
perform these performance requirements. For example, the thickness
of the MgO board 102 and/or the thickness and/or material of the
substrate 104 can be varied to meet ever increasing design
requirements or changing building codes. In another example, the
adhesive 106 used in fabricating the laminate 100 can be varied to
provide laminates 100 that meet varying permeances of vapor retards
specified in the building codes.
[0049] FIG. 2 is a flow chart illustrating a process 200 to
manufacture a laminated building material, such as the laminate
100. At step 202, the process 200 provides sheathing, such as the
MgO cement based sheathing 102 and at step 202 the process 200
provides the substrate 104.
[0050] At step 206, the adhesive 106 is applied. In an embodiment,
a roller-coater process applies the adhesive. Other methods of
applying the adhesive 106 comprise rolling by hand, painting,
spraying, and the like. The adhesive is preferably applied evenly
over the surface. The wet film weight of the applied adhesive 106
when measured with a standard scale ranges from approximately 22
grams per square foot to approximately 30 grams per square foot,
and preferably is not less than approximately 26 grams per square
foot and not more than approximately 30 grams per square foot. In
an embodiment, the adhesive 106 is applied to the top layer 102. In
another embodiment, the adhesive 106 is applied to the substrate
104. The layer 102, 104 without the adhesive 106 is placed on top
of the layer 102, 104 coated with the adhesive 106.
[0051] In another embodiment, at step 206, the process 200 uses a
roll press lamination process with a suitable pressure sensitive
adhesive to laminate the top layer 102 to the substrate 104.
[0052] At step 208, the process 200 cures the laminate under
pressure. In an embodiment, the laminate 100 is place in a press
and cured under a pressure of approximately 10 psi to approximately
14 psi, and preferably approximately 12 psi. In one embodiment, the
adhesive 106 comprises a latex-based adhesive and the curing time
ranges from about 20 minutes to about 30 minutes. In addition, the
curing time may vary with the temperature of the curing
environment, such that less time may needed to cure the laminate
100 when it is hot, and more time may be needed when it is cool. In
other embodiments, other adhesives 106 are used, and the curing
time varies based on the adhesive and the temperature.
[0053] At step 210, the process 200 optionally applies a finish to
the laminate 100. For example, the edges of the laminate 100 could
be sealed to restrict water absorption by painting the edges with
paint or other sealer, the surface of the laminate 100 could be
painted, covered with stucco, or the like, a wood grain or other
texture could be formed in the laminate 100 or formed during the
fabrication of the MgO board 102, another layer, such as a wood
layer with a wood grain finish could be laminated to the laminate
100, and the like. The finishing step 210 can be performed during
the fabrication of the laminate 100, at a constructions site, or at
any other time.
Installation
[0054] The laminate 100 may be installed on interior or exterior
walls. The laminate can be installed using a compatible adhesive,
mechanical fasteners, such as screws, nails, and the like, or a
combination. The laminate 100 may be applied to wood or steel
framing.
Building Product Embodiments
[0055] In addition, by using MgO laminated products, many other
building products can be made with the added performance of the MgO
layer 102. One example of an MgO laminated building product is a
laminated fire resistant joist. FIG. 3 illustrates typical framing
construction 300 comprising traditional wooden joists 302. In an
embodiment, the joists 302 comprise timber, plywood, OSB, and the
like. The joists 302 above one or more studs are being used as
roofing joists and the joists 302 below a floor 306 are being used
as flooring joists, in the illustrated example in FIG. 3.
[0056] FIG. 4 illustrates a typical wooden I-joist 400 comprising a
web or vertical element 404 inserted in the grooves of upper and
lower flanges or horizontal elements 402a, 402b, respectively. In
an embodiment, the joist 400 comprises a Truss Joist I-beam.TM.
(.TM.). In an embodiment, the flanges 402 and the web 404 comprise
wood, plywood, OSB, and the like.
[0057] FIG. 5 illustrates a laminated fire resistant joist 500
comprising the joist 300 laminated with MgO cement based boards
502, 504, 506, 508, 510. In the illustrated embodiment, MgO board
502 is laminated to a first side of the joist 300; MgO board 504 is
laminated to a second side of the joist 300; MgO board 506 is
laminated to a third or top side of the joist 300, MgO board 508 is
laminated to a fourth or bottom side of the joist 300; MgO board
510 is laminated to a first end of the joist 300; and MgO board 512
is laminated to a second end of the joist 300. In an embodiment,
the MgO boards 502-512 encompass, surround, enclose, encase or
envelop the joist 300.
[0058] In an embodiment, boards 502-512 comprise Magnesium Oxide
(MgO) cement based boards or sheathing. In another embodiment, the
MgO cement boards 502-512 are structural and comprise
fiberglass-reinforced MgO cement boards. In a further embodiment,
the boards 502-512 comprise MagBoard.TM..
[0059] In an embodiment, the fire resistant joist 500 is a fire
resistant floor and roof joist. The joist 500 encases the wooden
joist 300 and provides the fire, insect, mold, mildew, and rot
protection associated with the MgO boards.
[0060] FIG. 6 illustrates a laminated fire resistant joist 600. The
joist 600 comprises the joist 400 laminated with MgO cement based
boards. In the illustrated embodiment, an upper surface of the
upper flange 402a and a lower surface of the lower flange 402b are
laminated with the MgO cement based boards 602a, 602b,
respectively, and the first and second sides of the web 404 are
laminated with the MgO cement based boards 604a, 604b,
respectively. In a further embodiment, the front end and the back
end of the joist 400 are laminated with MgO boards cement based
boards 606a and 606b (not illustrated), respectively. In an
embodiment, the MgO boards 602-606 encompass, surround, enclose,
encase, or envelop the joist 400.
[0061] In an embodiment, boards 602-606 comprise Magnesium Oxide
(MgO) cement based boards or sheathing. In another embodiment, the
MgO cement boards 602-606 are structural and comprise
fiberglass-reinforced MgO cement boards. In a further embodiment,
the boards 602-606 comprise MagBoard.TM..
[0062] Laminated joists 500, 600 comprise similar flame spread and
smoke generation numbers as those for MagBoard included on Tables
A, C, and D. As discussed above, the flame spread for the laminated
joist 500, 600 is approximately zero and the smoke generation
number is approximately zero. Similarly, floor and roofing joists
made of unprotected OSB comprise similar flame spread and smoke
generation numbers as standard OSB, such as a flame spread rating
of approximately 148 and a smoke generation rating of approximately
137.
[0063] Thus, the laminated joist 500, 600 has substantially
increased the flame resistance and smoke spread characteristics of
joists constructed of OSB or a similar material alone. The
resulting laminated joist 500, 600 comprises a fire resistant joist
having the enhanced fire and structural performance associated with
the MgO cement board to meet new and more stringent fire codes,
while also providing water, insect, and mold and rot
protection.
[0064] While specific embodiments of, and examples for, the
invention are described above for illustrative purposes, various
equivalent modifications are possible within the scope of the
invention, as those ordinary skilled in the relevant art will
recognize. For example, other substrates, such as metal, foam,
fiberglass reinforced plastic, plywood and the like, can be
laminated to magnesium oxide boards to provide the laminate with
enhanced characteristics provided by the magnesium oxide board. In
another example, other OSB or wood building products, such as
melamine, particle board, high density chip board, and the like can
be laminated with magnesium oxide board to enhance the laminated
products with the characteristics of the magnesium oxide board.
Terminology
[0065] The above detailed description of certain embodiments is not
intended to be exhaustive or to limit the invention to the precise
form disclosed above. While specific embodiments of, and examples
for, the invention are described above for illustrative purposes,
various equivalent modifications are possible within the scope of
the invention, as those ordinary skilled in the relevant art will
recognize. For example, while processes or blocks are presented in
a given order, alternative embodiments may perform routines having
steps, or employ systems having blocks, in a different order, and
some processes or blocks may be deleted, moved, added, subdivided,
combined, and/or modified. Each of these processes or blocks may be
implemented in a variety of different ways. Also, while processes
or blocks are at times shown as being performed in series, these
processes or blocks may instead be performed in parallel, or may be
performed at different times.
[0066] Unless the context clearly requires otherwise, throughout
the description and the claims, the words "comprise," "comprising,"
and the like are to be construed in an inclusive sense, as opposed
to an exclusive or exhaustive sense; that is to say, in the sense
of "including, but not limited to." The words "proportional to", as
generally used herein refer to being based at least in part on. The
words "coupled" or connected", as generally used herein, refer to
two or more elements that may be either directly connected, or
connected by way of one or more intermediate elements.
Additionally, the words "herein," "above," "below," and words of
similar import, when used in this application, shall refer to this
application as a whole and not to any particular portions of this
application. Where the context permits, words in the above Detailed
Description using the singular or plural number may also include
the plural or singular number respectively. The word "or" in
reference to a list of two or more items, that word covers all of
the following interpretations of the word: any of the items in the
list, all of the items in the list, and any combination of the
items in the list.
[0067] Moreover, conditional language used herein, such as, among
others, "can," "could," "might," "may," "e.g.," "for example,"
"such as" and the like, unless specifically stated otherwise, or
otherwise understood within the context as used, is generally
intended to convey that certain embodiments include, while other
embodiments do not include, certain features, elements and/or
states. Thus, such conditional language is not generally intended
to imply that features, elements and/or states are in any way
required for one or more embodiments or that one or more
embodiments necessarily include logic for deciding, with or without
author input or prompting, whether these features, elements and/or
states are included or are to be performed in any particular
embodiment.
[0068] The teachings of the invention provided herein can be
applied to other systems, not necessarily the systems described
above. The elements and acts of the various embodiments described
above can be combined to provide further embodiments.
[0069] While certain embodiments of the inventions have been
described, these embodiments have been presented by way of example
only, and are not intended to limit the scope of the disclosure.
Indeed, the novel methods and systems described herein may be
embodied in a variety of other forms; furthermore, various
omissions, substitutions and changes in the form of the methods and
systems described herein may be made without departing from the
spirit of the disclosure. The accompanying claims and their
equivalents are intended to cover such forms or modifications as
would fall within the scope and spirit of the disclosure.
* * * * *