Reinforced Cementitious Shear Panels

Abstract

This invention relates to a structural cementitious panel (SCP) panel able to resist lateral forces imposed by high wind and earthquake loads in regions where they are required by building codes. These panels may be used for shear walls, flooring or roofing or other locations where shear panels are used in residential or commercial construction. The panels employ one or more layers of a continuous phase resulting from the curing of an aqueous mixture of inorganic binder reinforced with glass fibers and containing lightweight filler particles. One or more reinforcement members, such as mesh or plate sheets, are bonded to at least one surface of the panel to provide a completed panel that can breathe and has weather resistant characteristics to be capable of sustaining exposure to the elements during construction, without damage.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a first embodiment of a reinforced structural cementitious panel (SCP) panel of the present invention employing strips of reinforcing sheets inserted in indentations on the SCP material of the panel.

FIG. 2 is a cross-sectional view along view II-II of the panel of FIG. 1.

FIG. 3 is a top view of a second embodiment of a reinforced SCP panel of the present invention employing strips of reinforcing sheets, including strips which wrap around opposed edges of the panel.

FIG. 4 is a cross-sectional view along view IV-IV of the panel of FIG. 3.

FIG. 5 is a top view of a third embodiment of a reinforced SCP panel of the present invention wherein the reinforcement strips protrude from a surface of the panel.

FIG. 6 is a cross-sectional view along view VI-VI of the panel of FIG. 5.

FIG. 7 is a top view of a fourth embodiment of a reinforced SCP panel of the present invention including reinforcing strips which wrap around opposed sidewalls of the panel.

FIG. 8 is a cross-sectional view along view VIII-VIII of the panel of FIG. 7.

FIG. 9 is a perspective view of a fifth embodiment of a reinforced SCP panel of the present invention including reinforcing mesh which wrap around opposed walls of the panel.

FIG. 10 is a top view of a sixth embodiment of a reinforced SCP panel of the present invention including reinforcing corner pieces and separate optional reinforcing strips.

FIG. 11 is a cross-sectional view along view XI-XI of the panel of FIG. 10.

FIG. 12 is a cross-sectional view along view XII-XII of the panel of FIG. 10.

FIG. 13 is a top view of a seventh embodiment of a reinforced SCP panel of the present invention including reinforcing strips and separate reinforcing corner pieces. Optionally, two of the reinforcing strips contact the corner pieces.

FIG. 14 is a cross-sectional view along view XIV-XIV of the panel of FIG. 13.

FIG. 15 is a cross-sectional view along view XV-XV of the panel of FIG. 13.

FIG. 16 is a top view of an eighth embodiment of a reinforced SCP panel of the present invention employing a one piece reinforced border on one of its surfaces.

FIG. 17 is a cross-sectional view along view XVII-XVII of the panel of FIG. 16.

FIG. 18 is a top view of a ninth embodiment of a reinforced SCP panel of the present invention employing a multi-piece reinforced border on one of its surfaces.

FIG. 19 is a top view of a tenth embodiment of a reinforced SCP panel of the present invention employing a perforated panel.

FIG. 20 is a cross-sectional view along view XX-XX of the panel of FIG. 19.

FIG. 21 is a perspective view of the panel of FIG. 19.

FIG. 22 is a perspective view of a portion of an eleventh embodiment of a reinforced SCP panel of the present invention employing a panel with small perforations.

FIG. 23 is a top view of a portion of a twelfth embodiment of a reinforced SCP panel of the present invention employing a panel with small perforations.

FIG. 24 is a cross-sectional view along view XXIV-XXIV of the panel of FIG. 23.

FIG. 25 is a top view of a portion of a thirteenth embodiment of a reinforced SCP panel of the present invention.

FIG. 26 is a cross-sectional view along view XXVI-XXVI of the panel of FIG. 25.

FIG. 27 is a top view of a portion of a fourteenth embodiment of a reinforced SCP panel of the present invention.

FIG. 28 is a cross-sectional view along view XXVIII-XXVIII of the panel of FIG. 27.

FIG. 29 is a side view of a multi-layer SCP panel of the present invention with the reinforcement omitted for clarity.

FIG. 30 is a schematic side view of a metal frame wall suitable for employing with a reinforced structural cementitious panel (SCP) panel of the present invention.

FIG. 31 is an elevation view of an apparatus which is suitable for making the SCP panel of the present invention, except for a downstream embossing station and reinforcement attaching station.

FIG. 32 is a perspective view of a slurry feed station of the type used in the present process.

FIG. 33 is a fragmentary overhead plan view of an embedment device suitable for use with the present process to embed lightweight filler.

FIG. 34 shows ASTM E72 Racking data of five 8 foot×8 foot (2.16 m×2.16 mm) samples with SCP installed horizontally on 16 gauge 3.624 steel studs at 16 inches on center with fastener layout of 6″ (15.2 cm) on center on the perimeter and 12″ (30.4 cm) in the field.

FIG. 35 is a perspective view of a typical metal floor frame 160 suitable for use with the reinforced SCP panels of the present invention.

FIG. 36 is a fragmentary schematic vertical section of a single-layer SCP panel 162 supported on metal frame of FIG. 35 in a system of the present invention.

FIG. 37 is a perspective view of SCP panels of FIG. 36 supported on a corrugated sheet in the non-combustible flooring system of the present invention.

FIG. 38 shows a perspective view of a portion of the embodiment of FIG. 37 wherein SCP panel is attached to corrugated sheet with metal screws.

FIG. 39 shows an embodiment of a roofing system using the reinforced SCP panels of the present invention.

FIG. 40 shows another embodiment of a roofing system using the reinforced SCP panels of the present invention.

Claims

1. A panel for resisting shear loads when fastened to framing, comprising: a panel of a continuous phase resulting from the curing of an aqueous mixture comprising, on a dry basis, 35 to 70 weight % reactive powder, 20 to 50 weight % lightweight filler, and 5 to 20 weight % glass fibers, the continuous phase being reinforced with glass fibers and containing the lightweight filler particles, the lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers); andat least one reinforcing member selected from the group consisting of plate and a mesh sheet attached to a first surface of the continuous phase panel, wherein the at least one reinforcing member covers 5 to 90% of the first surface of the continuous phase panel.

2. The panel of claim 1 further comprising: a first backing sheet attached to the continuous phase on the first planar surface of the panel; and a second backing sheet attached to the continuous phase on a second planar surface of the panel.

3. The panel of claim 1 wherein the reinforcing member comprises material selected from the group consisting of steel, aluminum, wood and plastic.

4. The panel of claim 1 wherein the reinforcing member comprises rectangular strips placed in depressions on the surface of the continuous phase.

5. The panel of claim 1, wherein the at least one reinforcing member comprises rectangular strips placed in depressions on the surface of the continuous phase such that an upper surface of the respective rectangular strips is substantially flush with an upper surface of the continuous phase.

6. The panel of claim 1, wherein the at least one reinforcing member comprises rectangular strips, wherein an upper surface of the respective rectangular strips protrudes from an upper surface of the continuous phase.

7. The panel of claim 1, wherein the at least one reinforcing member comprises strips of reinforcing sheets having an L-shaped transverse cross-section and respectively wrap around opposed edges of the panel.

8. The panel of claim 1, wherein the at least one reinforcing plate reinforcing strips which wrap around opposed sidewalls of the continuous phase of the panel.

9. The panel of claim 1, wherein the at least one reinforcing member comprises reinforcing mesh having a U-shaped transverse cross-section which wraps around opposed walls of the continuous phase of the panel.

10. The panel of claim 1, wherein the at least one reinforcing member comprises a sheet of mesh wrapped around opposed surfaces of the continuous phase of the panel.

11. The panel of claim 1, wherein the at least one reinforcing member comprises separate reinforcing corner pieces and optional reinforcing strips attached the continuous phase of the panel.

12. The panel of claim 1, wherein the at least one reinforcing member comprises a central reinforcing strip and separate reinforcing corner pieces, optionally, the panel is further provided with two reinforcing strips which contact the corner pieces.

13. The panel of claim 1, wherein the at least one reinforcing member comprises a one piece reinforced border having an outer perimeter at or adjacent a perimeter of one of the surfaces of the continuous phase of the panel and an inner perimeter.

14. The panel of claim 1, wherein the at least one reinforcing member comprises a reinforcing border having an outer perimeter at or adjacent a perimeter of one of the surfaces of the continuous phase of the panel and an inner perimeter, wherein the reinforcing border comprises a multi-piece reinforcing border on one of the surfaces of the continuous phase, the reinforcing border comprising corner pieces, longitudinal side pieces and transverse side pieces.

15. The panel of claim 1, wherein the at least one reinforcing member comprises a panel, having perforations, attached to the continuous phase.

16. The panel of claim 1, wherein the panel comprises: a core layer comprising the continuous phase, andat least one outer layer of respectively another continuous phase resulting from the curing of an aqueous mixture comprising, on a dry basis, 35 to 70 weight % reactive powder, 20 to 50 weight percent lightweight filler, and 5 to 20 weight % glass fibers, the continuous phase being reinforced with glass fibers and containing the lightweight filler particles, the lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers) on each opposed side of the inner layer, wherein the at least one outer layer has a higher percentage of glass fibers than the inner layer.

17. The panel of claim 1, wherein the continuous phase results from the curing of an aqueous mixture of reactive powders comprising, on a dry basis, 35 to 75 wt. % calcium sulfate alpha hemihydrate, 20 to 55 wt. % hydraulic cement, 0.2 to 3.5 wt. % lime, and 5 to 25 wt. % of an active pozzolan, the continuous phase being uniformly reinforced with alkali-resistant glass fibers and containing uniformly distributed lightweight filler particles comprising uniformly distributed ceramic microspheres.

18. The panel of claim 17, wherein the ceramic microspheres have a mean particle size from 50 to 250 microns and/or fall within a particle size range of 10 to 500 microns

19. The panel of claim 1, wherein the panel has been formed from 35 to 58 wt. % of the reactive powders, 6 to 17 wt. % of the glass fibers, and 34 to 49 wt. % of at least one the lightweight filler selected from the group consisting of ceramic microspheres, glass microspheres, fly ash cenospheres or perlite, each on a dry basis.

20. The panel of claim 1, wherein the panel has been formed from 49 to 56 wt. % of the reactive powders, 7 to 12 wt. % of the glass fibers, and 35 to 42 wt. % of ceramic microspheres, each on a dry basis, the ceramic microspheres having a particle density of 0.50 to 0.80 g/mL.

21. The panel of claim 1, wherein the filler comprises uniformly distributed glass microspheres and/or fly ash cenospheres having an average diameter of about 10 to 350 microns (micrometers).

22. The panel of claim 1, wherein the panel is formed from 42 to 68 wt. % of the reactive powders, 5 to 15 wt. % of the glass fibers, 23 to 43 wt. % of ceramic spheres, and up to 1.0 wt. % of glass microspheres, each on a dry basis.

23. The panel of claim 1, wherein the panel comprises a core comprising the continuous phase resulting from the curing of an aqueous mixture of reactive powders comprising, on a dry basis, 35 to 75 wt. % calcium sulfate alpha hemihydrate, 20 to 55 wt. % hydraulic cement, 0.2 to 3.5 wt. % lime, and 5 to 25 wt. % of an active pozzolan, the continuous phase being uniformly reinforced with the alkali-resistant glass fibers and containing the lightweight filler comprising uniformly distributed ceramic microspheres, and further comprising at least one outer layer, each the outer layer comprising a continuous phase resulting from the curing of an aqueous mixture of reactive powders comprising, on a dry basis, 35 to 75 wt. % calcium sulfate alpha hemihydrate, 20 to 55 wt. % hydraulic cement, 0.2 to 3.5 wt. % lime, and 5 to 25 wt. % of an active pozzolan, the continuous phase being uniformly reinforced with alkali-resistant glass fibers, and lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers), at least one outer layer having reduced phase density relative to the core.

24. The panel of claim 1, wherein the outer layer(s) has been formed from 42 to 68 wt. % of the reactive powders, 5 to 15 wt. % of the glass fibers, up to 1.0 wt. % of glass microspheres having an average diameter of about 10 to 350 microns (micrometers), and 23 to 43 wt. % of the lightweight filler particles comprising ceramic spheres, each on a dry basis.

25. The panel of claim 1, wherein the panel has a thickness of about ¼ to 1½ inches (6.3 to 38.11 mm).

26. The panel of claim 1, wherein the outer layers have a thickness of about 1/32 to 4/32 inches (0.8 to 3.2 mm).

27. The panel of claim 1, wherein the flexural strength of a panel having a dry density of 65 lb/ft3 (1041 kg/m3) to 90 lb/ft3 after being soaked in water for 48 hours is at least 1000 psi (7 MPa) as measured by the ASTM C 947 test.

28. The panel of claim 1, wherein the flexural strength of a panel having a dry density of 65 lb/ft3 (1041 kg/m3) to 90 lb/ft3 after being soaked in water for 48 hours is at least 1650 psi (11.4 MPa) as measured by the ASTM C 947 test.

29. The panel of claim 1, wherein the hydraulic cement is Portland cement.

30. The panel of claim 1, wherein the reactive powders comprise 45 to 65 wt. % calcium sulfate hemihydrate, 25 to 40 wt. % hydraulic cement, 0.75 to 1.25 wt. % lime, and 10 to 15 wt. % of an active pozzolan.

31. The panel of claim 1, which, when fastened to wall framing, has a racking shear strength between 1.1 and 3.0 times the racking shear strength of a similar SCP panel without reinforcing that is fastened to the same wall framing with the same fasteners.

32. A non-combustible system for construction comprising: a shear diaphragm supported on metal frame, the shear diaphragm comprising a panel for resisting shear loads when fastened to framing, comprising:a panel of a continuous phase resulting from the curing of an aqueous mixture comprising, on a dry basis, 35 to 70 weight % reactive powder, 20 to 50 weight % lightweight filler, and 5 to 20 weight % glass fibers, the continuous phase being reinforced with glass fibers and containing the lightweight filler particles, the lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers); andat least one reinforcing member selected from the group consisting of plate and a mesh sheet attached to a first surface of the continuous phase panel, wherein the at least one reinforcing member covers 5 to 90% of the first surface of the continuous phase panel.the frame comprising metal framing members,wherein the panel has a thickness of ¾ inch and has a racking strength ultimate load measured according to ASTM E72 racking from about 4400 to 7400 lbs for an 8 foot by 8 foot wall assembly.

33. The system of claim 32, wherein the racking strength ultimate load is in the range of from about 4600 to about 6000 lbs for an 8 foot by 8 foot wall assembly.

34. The system of claim 32, comprising a first said panel and a second said panel on opposed sides of the framing, respectively.