U.S. patent application number 16/504188 was filed with the patent office on 2020-01-09 for construction assembly made with fiber glass.
The applicant listed for this patent is Naser Saniepey. Invention is credited to Naser Saniepey.
Application Number | 20200011065 16/504188 |
Document ID | / |
Family ID | 69101878 |
Filed Date | 2020-01-09 |
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United States Patent
Application |
20200011065 |
Kind Code |
A1 |
Saniepey; Naser |
January 9, 2020 |
CONSTRUCTION ASSEMBLY MADE WITH FIBER GLASS
Abstract
Provided is a construction assembly comprising: a. a base; b. a
layer of glass fiber placed directly on the base; and c. a
decorative layer having a plurality of tiles placed immediately on
the glass fiber, wherein the glass fiber is mixed with a hardener
and a resin to attach the glass fiber directly to the base and the
decorative layer.
Inventors: |
Saniepey; Naser; (Costa
Mesa, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Saniepey; Naser |
Costa Mesa |
CA |
US |
|
|
Family ID: |
69101878 |
Appl. No.: |
16/504188 |
Filed: |
July 5, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62694891 |
Jul 6, 2018 |
|
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16504188 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 2260/026 20130101;
E04F 13/0862 20130101; E04F 13/0875 20130101; B32B 2250/03
20130101; B32B 2419/04 20130101; B32B 21/042 20130101; B32B 17/04
20130101; E04F 13/0866 20130101; B32B 2451/00 20130101; B44C 5/0423
20130101 |
International
Class: |
E04F 13/08 20060101
E04F013/08; B44C 5/04 20060101 B44C005/04 |
Claims
1. A construction assembly comprising: a. a base; b. a layer of
glass fiber placed directly on the base; and c. a decorative layer
having a plurality of tiles placed immediately on the glass fiber,
wherein the glass fiber is mixed with a hardener and a resin to
attach the glass fiber directly to the base and the decorative
layer.
2. The construction assembly of claim 1, wherein the hardener
percentage compared to the resin is between 1%-2% weight/weight at
STP.
3. The construction assembly of claim 1, wherein the glass fiber is
in form of a sheet.
4. The construction assembly of claim 1, wherein the glass fibers
are in form of chopped fibers.
5. The construction assembly of claim 1, wherein an additional
chemical compound acting an adhesive is not used in between the
fiber glass and the decorative layer.
6. The construction assembly of claim 1, wherein the resin is
selected from the group consisting of one or more of polyester,
vinyl ester, epoxy resin, isophthalic, and mixture thereof.
7. The construction assembly of claim 1, wherein the resin is a
polyester resin, the hardener is Methyl Ethyl Ketone Peroxide
(MEKP).
8. The construction assembly of claim 7, wherein the combination of
the percentage of the hardener is 1 to 1.25 relative to the
polyester weight/weight at STP.
9. The construction assembly of claim 7, wherein the combination of
the percentage of the hardener is 1 to 1.1 relative to the
polyester weight/weight at STP.
10. The construction assembly of claim 1, wherein the base is made
from wood, metal or concrete.
11. The construction assembly of claim 1, wherein the base is made
from wood with a pre-applied layer of caulking to fill any of the
gaps of the base.
12. The construction assembly of claim 1, wherein the hardener is
an aliphatic, cycloaliphatic, or an aromatic amine and the resin is
epoxy based.
13. The construction assembly of claim 1, wherein Calcium Carbonate
is added to the mixture of the hardener and the resin.
14. A construction assembly made by a process comprising the steps
of: a. combining a hardener with a resin to obtain a mixture; b.
placing glass fibers on top of a base; c. applying the mixture to
the glass fibers on the wood; and d. placing tiles on the glass
fibers that area treated by the mixture.
15. A roof construction assembly comprising: a. a top and a bottom
board made from wood; b. a plurality of rafters for connecting the
boards; c. a plurality of plastic foams placed on between the
rafters; and d. a layer of glass fiber under the bottom layer.
16. The roof assembly of claim 15, wherein the construction
assembly is prefabricated.
17. The roof assembly of claim 15, further comprising a bracket
extending from top of the assembly.
18. The roof assembly of claim 15, further comprising a layer of
glass fiber on top of the top board, and a plurality of decorative
elements on top of the fiberglass.
19. The roof assembly of claim 15, wherein the plastic foams are in
form of a sheet.
20. The roof assembly of claim 15, wherein the layer of fiberglass
is all around the assembly.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority to U.S.
provisional application Ser. No. 62/694,891, filed on Jul. 6, 2018,
the contents of which are hereby incorporated by reference.
BACKGROUND SECTION OF THE INVENTION
[0002] There are many places in a structure where tiles are placed,
including walls, decks, roofs, flooring, and building facades. A
problem with structures having tiles is that the structure may too
rigid, resulting in excess noise when a person walks on a tile or
resulting in breaking of the tiles. In addition, the underlying
wood of the structure may be prone to a termite infestation. In
case of a roof, the pre-existing structures are prone to fires,
wind, and lack of uniformity and insulation. There is a need in the
art for a construction method and structure that addresses these
drawbacks.
SUMMARY SECTION OF THE INVENTION
[0003] Provided is a construction assembly comprising: a. a base;
b. a layer of glass fiber placed directly on the base; and c. a
decorative layer having a plurality of tiles placed immediately on
the glass fiber, wherein the glass fiber is mixed with a hardener
and a resin to attach the glass fiber directly to the base and the
decorative layer. The hardener percentage compared to the resin can
be between 1%-2% weight/weight at STP. The glass fiber can be in
form of a sheet. The glass fibers can be in form of chopped fibers.
Optionally, an additional chemical compound acting an adhesive is
not used in between the fiber glass and the decorative layer. The
resin can be selected from the group consisting of one or more of
polyester, vinyl ester, epoxy resin, isophthalic, and mixture
thereof. The resin can be a polyester resin, the hardener is Methyl
Ethyl Ketone Peroxide (MEKP). The combination of the percentage of
the hardener can be 1 to 1.25 relative to the polyester
weight/weight at STP. The combination of the percentage of the
hardener can be 1 to 1.1 relative to the polyester weight/weight at
STP. The base can be made from wood, metal or concrete. The base
can be made from wood with a pre-applied layer of caulking to fill
any of the gaps of the base. The hardener can be an aliphatic,
cycloaliphatic, or an aromatic amine and the resin is epoxy based.
Calcium Carbonate is added to the mixture of the hardener and the
resin.
[0004] Provided is a construction assembly made by a process
comprising the steps of: a. combining a hardener with a resin to
obtain a mixture; b. placing glass fibers on top of a base; c.
applying the mixture to the glass fibers on the wood; and d.
placing tiles on the glass fibers that area treated by the
mixture.
[0005] Provided is a roof construction assembly comprising: a. a
top and a bottom board made from wood; b. a plurality of rafters
for connecting the boards; c. a plurality of plastic foams placed
on between the rafters; and d. a layer of glass fiber under the
bottom layer. The construction assembly can be prefabricated. A
bracket can extend from top of the assembly. A layer of glass fiber
can be on top of the top board, and a plurality of decorative
elements on top of the fiberglass. The plastic foams can be in form
of a sheet. A level of cement or gypsum can be below the glass
fiber on the bottom board. The layer of fiberglass can be all
around the assembly.
BRIEF DESCRIPTION OF THE FIGURES
[0006] FIG. 1 illustrates a cross-section view of an assembly with
a wood base, a fiberglass layer, and a decorative layer of tiles.
Also illustrated is plaster used to fill the gaps between the tiles
and deformities in the wood base.
[0007] FIG. 2 illustrates the steps of the process in making the
assembly.
[0008] FIG. 3A illustrates a pre-fabricated roof section or panel
box.
[0009] FIG. 3B illustrates a blow-up of FIG. 3A.
[0010] FIG. 4 illustrates chopped glass fibers.
[0011] FIG. 5 illustrates a glass fiber sheet.
[0012] FIG. 6 illustrates a metal wall/panel before installation of
tiles.
[0013] FIG. 7 illustrates the metal wall/panel of FIG. 6 after tile
installation.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Provided is a method for putting tiles 3 and other similar
decorative products on walls, decks, roofs, flooring, building
facades, kitchen counters, walls, and patio grills. The base 1 of
the structure can be a wooden or metal base. The base 1 can be
perforated or non-perforated metal, wood, GRP (Glass Reinforced
Plastic), or FRP (Fiber-reinforced plastic) structure. A fiberglass
2 layer is placed immediately above the base 1 in physical contact
with the base 1, and decorative members such as tiles 3 and stones
on top, also in physical contact with the fiber glass 2 layer.
These products are easy to install, strong and leak proof. They are
also fire, cold, warm, wind and sunlight resistant, and therefore
have high durability. This method of construction can be used in
many different applications especially in custom designed houses,
residential homes, and apartments. Other uses include use in
overhead shades for parking and solar panels.
[0015] The base 1 can be made from a perforated or non-perforated
metal, wood, GRP (Glass Reinforced Plastic), or FRP.
Fiber-reinforced plastic (FRP) (also called fiber-reinforced
polymer, or fiber-reinforced plastic) is a composite material made
of a polymer matrix reinforced with fibers. The base 1 can for
example be a drywall or floor for placement of a tile. The base 1
can be the wooden support of a roof.
[0016] Glass fibers 2 are put immediately on top of the base 1.
Fiberglass 2 layers, with different fabric reinforcements such as
cloth, matt, roving, KNYTEX (made with a stitch-bonding process by
combining layers of .+-.45.degree. unidirectional fabric with
chopped strand mat), with different weights, and different
materials such as E-Glass (alumino-borosilicate glass with less
than 1% w/w alkali oxides, mainly used for glass-reinforced
plastics), S-Glass (alumino silicate glass without CaO but with
high MgO content with high tensile strength), carbon, graphite,
carbon fiber, and Aramid (TWARON and KEVLAR) can be used as the
fiber reinforcement.
[0017] Decorative products, such as tiles, stones, porcelain,
ceramic, and facade bricks are placed immediately on the glass
fiber 2.
[0018] To activate the glass fibers 2, a mixture 8 of a resin 31
and a catalyst hardener 30 is added to the glass 2 fibers. The
mixture 31 can further optionally have calcium carbonate 32. After
the mixture is applied to the glass fibers 2, the glass fibers 2
form a viscous sticky liquid, which is optimal for placement of
tiles. An additional layer of adhesive is not needed.
[0019] Examples of resins 31 include polyester, vinyl ester, epoxy
resin, and isophthalic.
[0020] Examples of hardeners 30 include Methyl Ethyl Ketone
Peroxide (MEKP) and amines, such an aliphatic, cycloaliphatic, or
an aromatic amine.
[0021] Hardener percentage can be between 1%-2% weight/weight
compared to the resin at STP (Standard temperature and
pressure).
[0022] Caulking 4, plaster and other filling agents can be used to
fill in between the tiles or fill in the base 1 (if perforated
metal, woven wire mesh or if the wood has imperfections).
[0023] The fiberglass 2 layer after activation with the
resin/hardener, acts as the binder between the base 1 structure and
the decorative products such as tiles 3.
[0024] Different resins 31 such as polyester, vinyl ester, epoxy
resin, or isophthalic and their hardeners 30 can be used in the
fiberglass 2 layers to adhere all the components together.
[0025] These construction assemblies can be either pre-made
(prefabricated) and get installed later or they can be made onsite
depending on the application. For example, in applications for
walls, precast sheets of this assembly can be attached to building
posts using bolts and nuts. For flooring applications, they can be
made onsite. For example, fiberglass 2 can be put on top of dried
cement and tiles 3, stones, and can be put on top, or the precast
sheets can be installed on top of cement using expansion anchor
bolts. For wooden roofs with small slopes, the layers of fiberglass
2 and then tiles 3, stones, bricks, or other materials can be
installed on top of it onsite. For high slope roofs, precast roofs
(as illustrated in FIG. 3A) can be used instead. If one of the
components is already present (for example, wooden roofs or
floors), the other two layers can be installed on site. In case of
light slopes or flat roofs it can be done on site otherwise in
steeped roofs, the precast option is used which is faster and
easier to install.
[0026] The base 1 layer can be made of wood, metal or concrete. The
preferred base 1 for use can be wood. When making the assembly, a
completely dry wood is used with all the cracks and small grooves
filled, such as with fiberglass 2. Caulking 4 can be used to fill
spaces between different boards. Use of resin 31 in fiberglass 2
makes the base 1 more resistant to termites.
[0027] After caulking 4, the surface can be leveled and smoothed by
sand paper. Two or three fiberglass 2 layers can be used for
ordinary roof/floor/deck/wall. To increase flexibility and
cushioning property of the roofs/floors/deck, especially when the
base 1 is made of wood, it is preferred to use excess layers of
fiberglass 2. In this embodiment, a combination of chopped fiber
glass (FIG. 4), hardener, and resin mixed and spread only over the
last layer with rollers can be used. In steeped roofs, the start
point is the lowest level of the roof. First, a layer of fiber
glass 2A is placed. The a galvanized, aluminum or stainless steel
angle/bracket 16 with the same thickness of tile/ceramic/porcelain
or stone is installed at the edge of wood (base 1) and tightened
with nail or screw (or other fastener) (as illustrated in FIG. 3A).
Application of fiberglass 2 layers can start from the vertical part
of the angle/bracket 16 and can extend to the highest point of the
roof, usually the ridge. The seams of fiberglass 2 layers optimally
do not coincide on each other and each layer overlaps with the next
layer. FIG. 3B is a blow-up of FIG. 3A.
[0028] Use of rollers to prevent formation of air bubbles is
preferred. After putting the second layer of fiberglass 2 let it
dry for 24 hours, then the third layer and tiles will be applied.
Caulking 4 will be done after 24 hours of putting tiles. Fiberglass
2 layer made of hardener 1% is more flexible than fiberglass 2 made
of denser hardener. Best temperature range is between 65-75 degrees
Fahrenheit. Fiberglass gel time is between 15-25 minutes depending
on temperature and amount of hardener. Best time for installing the
tiles is before gel time. Spacer can be used to build certain space
for caulking 4 between tiles. Final caulking 4 is preferably done
at least 24 hours after installing tiles. Different colors can be
added for a better look of caulking 4.
[0029] Perforated sheet metal used for a wall is preferred over
non-perforated because bilateral connection is made through the
holes. A layer of fiberglass 2 is attached to the surface of tile 3
(stones/ceramics/porcelains). An additional layer of fiber glass
can be used for heavier stones/ceramics/tiles. After 24 hours, when
it is completely dry, it would then adhere to fresh outer
fiberglass 2 layer of the wall/roof. The procedure of using
different resins is the same.
[0030] The following table illustrates the amount of MEKP used for
polyester and vinyl ester resin, preferably polyester resin:
TABLE-US-00001 Polyester Resin 1.25% Weight to weight 1% MEKP MEKP
1.5% MEKP 1.75% 4 ounces 1/32 Ounces 1.50 ounces 1.75 ounces
1/16+
[0031] Other resin and hardener combinations can also be used. For
example, if an epoxy resin is used, the hardener can be an
aliphatic, cycloaliphatic, or an aromatic amine for epoxy.
[0032] FIG. 1 illustrates a cross-section view of an assembly with
a wood base 1, a fiberglass 2 layer, and a decorative layer of
tiles. As illustrated in this drawing, a fiberglass layer 2 can be
placed on base 1. The fiber glass 1 can be in form of fibers of
FIG. 4 or sheets of FIG. 5. The fiber glass 2 is placed directly on
the base 1. Tiles 3 are based on top of the fiber glass 2. The
tiles 3 and the base 1 both adhere to fiber glass 2 without the
need for an additional adhesive layer. Caulking 4 can be used in
between the tiles 3.
[0033] FIG. 2 illustrates the steps of the process in making the
assembly. The fiber glass, either in form of sheets, chopped, or
mixtures thereof is placed 7 on the base 1. In a separate
container, a hardener is mixed 8 with a resin. The mix is applied
10 to the fiber glass. A roller can be used to make the application
uniform. Tiles 3 are placed 11 before the activated fiber glass is
hardened.
[0034] FIG. 3A illustrates a pre-fabricated roof section or a panel
box. The pre-fabricated roof section or other structure can be made
from a base 1 cover placed on top and another cover 13, placed on
the bottom. In one embodiment, base 1 and cover 13 are sheets of
wood. Board 1 can be thicker than board 13. Both boards 1 and 13
can be less than about one inch in thickness. Rafters 14 attach
base/sheet 1 to sheet 13. A plurality of rafters 14, preferably
also made out of wood, can be placed while maintaining a gap in
between them. Rafters 14 can also be made up of aluminum or FRP. A
water resistant material such as plastic sheet 50, such as plastic
foam (Styrofoam-closed-cell extruded polystyrene foam) (Yonolit)
can be placed in between the gaps of rafters 14 to add structural
flexibility and ability to withstand compression. Foamed plastic 50
is a synthetic resin converted into a sponge like mass with a
closed-cell or open-cell structure. The height/thickness of the
rafters 14 can be the same as that of the plastic sheet 50. Bracket
16 can be installed all along one or more sides of the base 1 for
holding tiles 3 in place on case the roof has an angle. The bracket
16 can be put on the bottom of the incline and the two sides. The
prefabricated roof can come with an optional layer of fiber glass
2A all around. Layer 2A can increase the tensile strength of the
pre-fabricated roof or other assemblies in the same manner that a
post-tension wire does. The pre-fabricated structure can have an
optional fiber glass layer 2A all or partially around the structure
(up to all six sides of the panel box). Just like FIG. 1, a fiber
glass layer is placed on base 1, and the tiles 3 are placed on top
of base 1, which is a wooden sheet. Caulking 4 can be used in
between the tiles. The pre-fabricated roof is placed on a wall or
column 51. The lower section of the roof that is placed inside the
structure can be covered with plaster/gypsum 18. Cement 17 can be
used to cover portions of the roof that are outside of the
structure. Instead of cement 17 and gypsum 18, decorative panels
and tiles can also be used. FIG. 3B is a blow-up of FIG. 3A.
[0035] FIG. 6 illustrates a metal wall 23 before installation of
tiles. Metal wall 23 can be held in place by posts 21 and top frame
22. Posts 21 can be held in place by attachment to concrete 20. A
gap can exist below metal wall 23. FIG. 7 illustrates installation
of tiles on both sides of wall 23, in the same way shown in FIG.
1.
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