Patent Application
20160158963
1. Field of the Invention
The present invention relates generally to panels used in building construction, and in particular, to such panels which are formed by mixing a plurality of substances, including magnesium oxide, into a layer and caused to quickly set and thereby form a panel which can be used for structural purposes.
2. Description of the Related Art
Currently known construction panels are formed of a combination of inorganic magnesium compounds, wood fibers, perlite, chemical additives, water and other substances which, after being mixed, are extruded onto a supporting surface on top of a PVC mold, between layers of glass fabric. The wet slurry mix is cut to the exact size of the mold and placed within the mold and then delivered on top of a movable metal rack to a curing room or space for drying. The mix is set to dry within the mold for several hours at room temperature. After which, the board is separated from the mold and left in a stack for several more hours to further dry. The panels are then trimmed and sanded to a uniform thickness and the process is complete.
It is apparent that several problems exist with the current process including that it is very costly and unduly lengthy. Considerable manpower is required over the course of several days. A large amount of space is necessary for storing the panels during curing. The glass fabric used for reinforcing the strength of the panel is costly and accounts for approximately twenty percent of the total cost of the raw materials required.
Furthermore, the current process represents a considerable amount of economic waste, including the raw materials wasted when the panels are trimmed and sanded.
Moreover, the construction panels suffer from a number of structural and environmental shortcomings. The magnesium chloride incorporated in the panel composition allows for leaching and breeding, substantially weakening the material. The flexural and shear strengths are also such that they leave the panels vulnerable to cracking or splitting. The glass fabric used, although alkaline resistant, eventually erodes the fabric gradually weakening the panels.
Thus, a faster, cost-friendly, environmentally conscience process resulting in a more stable product is highly desired.
It is, therefore, a primary object of the present invention to provide an improved magnesium oxide panel, and process for creating such panel, in a cost-efficient manner to increase the rate of manufacture and product turnover, while simultaneously decreasing avoidable cost.
It is another object of the present invention to provide an improved panel that presents a lower risk of cracking or splitting by having increased flexural and shear strength, is recyclable, and simultaneously increases the numerous positive characteristics that make the existing construction panels exceptional wallboards in the construction industry today.
It is another object of the present invention to provide an improved panel that twice as strong as the existing construction panels, while still maintaining superior resistance and durability to damage from fire and water.
It is another object of the present invention to provide an improved panel comprising a small percentage of magnesium oxide, low grade or recycled material, bamboo chips, chemical additive and water.
It is another object of the present invention to provide an improved panel no longer comprising glass fabric, magnesium chloride, neutralizing chemical additives, and perlite.
It is another object of the present invention to provide an improved panel free of leaching or breeding issues.
It is another object of the present invention to provide an improved panel comprising environmentally-friendly recycled material including dust after sanding, trimmings, and broken panels.
It is another object of the present invention to manufacture an improved panel with substantially desirable properties in a single day.
It is another object of the present invention to manufacture an improved panel in a process that bonds the semi-arid mix under pressure, in lieu of heat.
It is another object of the present invention to manufacture an improved panel in a process free of molds and racks.
In accordance with one aspect of the present invention, a manufactured panel is provided comprising a mixture of high purity magnesium oxide, low purity magnesium oxide, fibrous chips, and chemical additive dissolved in an aqueous solution. The high purity magnesium oxide may have a purity of at least 79%. The low purity magnesium oxide may have a purity of at least 20%. The low purity magnesium oxide mixture may further comprise recycled manufactured panels. The fibrous chips may be from the group consisting of wood and bamboo chips. The manufactured panel may be used to construct load bearing walls, non-load bearing walls, ceilings, roofing, siding, insulated walls, and tile backer.
In accordance with an additional embodiment a manufactured panel is provided comprising at least 5% magnesium oxide, at least 50% recycled magnesium oxide, at least 40% fibrous chips, and at least 5% chemical additive in an aqueous solution. The recycled magnesium oxide material may include recycled manufactured panel material. The fibrous chips may be from the group consisting of wood and bamboo chips.
In accordance with an additional embodiment, a method of manufacturing a construction panel is provided comprising preparing a semi-arid mixture of high purity magnesium oxide, low purity magnesium oxide, fibrous chips, and chemical additive in an aqueous solution. Then, pouring the semi-arid mixture through a funnel and dispensing the semi-arid mixture from the funnel onto a conveyor belt. Next, passing the dispensed semi-arid mixture through a roller, where the roller is configured to press and spread the semi-arid mixture against the conveyor belt to a layer of desired uniform thickness. Then, pressing the layer through a compressor, where the compressor is configured to remove excess liquid from the layer, before cutting the compressed layer into panels of predetermined length. The high purity magnesium oxide may have a purity of at least 79%. The low purity magnesium oxide may have a purity of at least 20%. The low purity magnesium oxide mixture may further comprise recycled manufactured panels. The fibrous chips may be from the group consisting of wood and bamboo chips.
The method may further comprise drying the panels, heating the panels to a desired temperature, and heating the panels by solar energy.
The method may further comprise passing the panels through a jet, where the jet is configured to spray dry magnesium oxide on the panels, and stacking the panels.
In accordance with an additional embodiment, a system for manufacturing a construction panel is provided comprising means for preparing a semi-arid mixture of high purity magnesium oxide, low purity magnesium oxide, fibrous chips, and chemical additive in an aqueous solution. The system includes means for dispensing the semi-arid mixture onto a conveyor belt, and means for spreading the semi-arid mixture against the conveyor belt to a layer of desired uniform thickness. The system includes means for removing excess liquid from the layer and means for cutting the layer into panels of predetermined length.
The system may further comprise means for drying the panels, means for spraying dry magnesium oxide onto the panels, and means for stacking the panels.
To these and to such other objects that may hereinafter appear, the present invention relates to improved magnesium-oxide based construction panels and the process for manufacturing same as described in detail in the following specification and recited in the annexed claims, taken together with the accompanying drawings, in which like numerals refer to like parts in which:
To the accomplishment of the above and related objects the invention may be embodied in the form illustrated in the accompanying drawings. Attention is called to the fact, however, that the drawings are illustrative only. Variations are contemplated as being part of the invention, limited only by the scope of the claims.
Referring now to
The construction panel 10 may be used in a variety of ways during the fabrication of a house or other type of structure. Without limitation, the construction panels 10 are used for constructing floors, walls, roofing, siding, and ceilings. By varying the height H of the panels, the constructed walls may be load bearing or non-load bearing.
The construction panel 10 is made from a composition comprising one or more of the following ingredients, magnesium oxide (MgO), recycled magnesium oxide, fibrous chips, wood chips, bamboo chips, water, and chemical additive.
In the preferred embodiment, the panels 10 are made using recycled magnesium oxide materials that are ground up excess portions (e.g. scraps) from prior fabrication processes. That is, as the panels are cut to size, sanded and trimmed, the leftover scraps and shavings are ground up and reused to make future panels. In the below table, the row labeled “New MgO” refers to the ingredients used to make the panels without reusing leftover board scraps from prior fabrication processes. The “New MgO” has a preferred purity of at least 79%. The row labeled “Recycled MgO” refers to ingredients used to make construction panels while reusing leftover panel scraps from prior manufacturing processes. The row labeled “Bamboo chips” refers to ingredients produced from a machine, which creates chips using the whole bamboo. In the preferred embodiment, the construction panel comprises ingredients listed below in Table 1.
In alternate embodiments, recycled MgO may be replaced with low-grade material having purity as low as 20%. In addition, bamboo chips may be replaced with wood or other fibrous chips. In one such alternate embodiment, the construction panel comprises ingredients listed below in Table 2.
The first step 110 of the method 100 includes mixing magnesium oxide with low grade or recycled board materials, and preferably fibrous or bamboo chips, and a chemical additive in an aqueous solution to create a semi-arid mixture. The second step 112 involves pouring the semi-arid mixture through a funnel. In the third step 114, the semi-arid mixture is dispensed through the funnel onto a conveyor belt. In the fourth step 116, the dispensed mixture is passed through a first roller. The first roller is configured to press the semi-arid mixture against the conveyor belt and form a panel layer of desired thickness. The fifth step 118 involves pressing the layer through a compressor, where the compressor is configured to remove excess liquid from the layer and compress the layer to a desired thickness. In the sixth step 120, the compressed layer is cut using a cutting blade, into panels of predetermined length. In the seventh step 122, the panels are cured by mild heat. Preferably, the conveyor belt delivers the panels to through tunnel, which exposes the panels to drying by at least one tunnel providing solar energy in order to raise the temperature of the panels from 30 degrees Celsius to 60 degrees Celsius plus or minus 5 degrees. After the panels pass through the solar energy in the tunnel, they are approximately 85% dry. In the eighth step 124, the panels pass through a powder puffing jet, where dry magnesium oxide is sprayed from the jet onto the panels. In the ninth step 126, the panels exit the conveyor belt and are stacked by a stacking machine on top of one another. Additional steps 128 may include further curing when the ambient temperature is warm or hot. Under extreme weather elements, it may take additional time for the panels to dry and cure 100%. However, even when the ambient temperature is as low as 6 degrees Celsius, it usually only takes a few hours for the panels to completely cure.
In conclusion, herein is presented improved magnesium-oxide based construction panels and the process for manufacturing same. The invention is illustrated by example in the drawing figures, and throughout the written description.
It should be understood that numerous variations are possible, while adhering to the inventive concept. Such variations are contemplated as being a part of the present invention.
While only a limited number of preferred embodiments of the present invention have been disclosed for purposes of illustration, it is obvious that many modifications and variations could be made thereto. It is intended to cover all of those modifications and variations, which fall within the scope of the present invention as defined by the following claims.
