Patent Application
20190276362
There is no cross reference applicable.
There is no federally sponsored research for this invention.
There is no such Sequence Listing applicable.
Currently in the building and construction industry there are different types of Structural Insulated Panel Systems (SIPS) that are available for builders to construct many different types of structures. The prior art of SIPS teaches many different manufacturing processes that utilize a variety of materials in producing the various types of SIPS. The various aspects taught by the invention are totally new approaches to manufacture SIPS both in terms of the selection of materials used in making the new and unique formulations/mixtures and the unique and improved manufacturing processes that are used to produce the SIPS of the invention. These new innovations of the invention produce desirable and noteworthy attributes to be further detailed.
SIPS: Is an insulating foam core sandwiched between two structural facings. The prior art teaches that the foam cores of a SIPS are without exception either an Expanded Polystyrene (EPS) or Spray Polyurethane Foam (SPF). The prior art further teaches that the two structural facings can be a variety of materials of which the two most widely manufactured types of SIPS are produced with oriented strand board (OSB) or magnesium oxide cement board/mag board as the structural facings and the foam core being either ESP or SPF.
The largest quantities of SIPS being manufactured in the US are typically manufactured by using oriented strand board (OSB) or modified wood substances for the two structural facings. These OSB type SIPS consist of an insulating foam core of expanded polystyrene (EPS) glued and sandwiched between two sheets of 7/16″ OSB. There are many short-comings in the prior art of SIPS technologies:
The second largest quantities of SIPS being manufactured in the US are typically manufactured by using magnesium oxide cement board (MOCB) in place of OSB as the two structural facings of the SIPS. This prior art has short comings in the technologies taught as well:
Note: The invention will make no further reference or comparison to the different types Structural Insulated Panel Systems (SIPS). The information provided on the different types SIPS were to simply detail the different types SIPS taught by the prior art. The invention creates a radically new classification/category/type of SIPS which utilizes totally new and unique formulations and mixtures of materials and unique and improved manufacturing processes not taught nor found in the prior art of SIPS.
The teaching of the invention articulates a SIPS consisting of an insulating Spray Polyurethane Foam (SPF) core sandwiched between two cement based structural facings. The invention will present the new and unique characteristics of the New Formulations/Mixtures and Unique and Improved Processes for Manufacturing Structural Insulated Panels Systems (SIPS) that qualify the invention in obtaining the right of Patent Protection by the USPTO for manufacturing the SIPS of the invention.
For the purposes of the invention being granted Patent Protection it is key that the new and unique formulations/mixtures for the two cement-based structural facings along the with the unique and improved manufacturing processes utilized in producing the SIPS of the invention be compared to historical methods of the poured/casted/formed cement based formulations/mixtures and processes taught by the prior art of building/construction industry as a whole. The invention is new and unique in its teaching of radically augmenting the typical cement-based methods of formulation and manufacturing processes taught by prior art. The invention then applies these new cement-based innovations to create unparalleled and new SIPS for the building/construction industry.
Historically the prior arts of the cement based formulations/mixtures of the building/construction industry over the last 160 years has taught that All cement-based formulations/mixtures must all utilize two types of reinforcements-(1) aggregates (sand and gravel) (2) Steel (rebar). This has been a mandatory prerequisite taught prior art without exception.
The prior art teaches that the aggregates (sand and gravel) are integrated or mixed with a cement paste (Portland cement) as a binding agent/element, which is the foundational ingredient, compound and or element of the cement-based formulations/mixtures, thus these formulations/mixtures are classified as cementitious mixtures.
The use of cement paste (Portland cement) as the binding agent/element of the formulations/mixtures in both the prior art and the invention are desirable, preferred, stable and is an unequalled binding agent in terms of being economical, widely available and durable for centuries. The cement paste/binding agent is by itself has a very dense, low/negligible porosity and does not dissolve, emulsify or transform from one state to another once the process of hydration sets the paste into a hardened crystallized state. In other words, it is very stable unlike the sand, gravel and steel reinforcements of the prior art.
It is widely thought that cement-based formulations/mixtures of the prior art are typically only reinforced with steel; when in fact the cement paste/binder is the base composite/matrix and it is reinforced with two reinforcements; 1) Aggregates (sand and gravel), 2 Steel (rebar). The aggregate (sand and gravel) are a localized form of reinforcements in that they are individual/separate small building blocks, which can suffer localized structural failure that in turn can lead into overall catastrophic structural failure. Although the content of sand and gravel are densely, thoroughly and uniformly present throughout the entirety of every single cubic inch of a cement-based formation they lack an interlocking/linked structural integrity of continuity. The cement paste, sand and gravel produce great comprehensive strengths but lack any tensile strengths. In contrast the steel reinforcement represents a very sparse density of the total volume in a cement-based formation. The steel produces the interlocking/linked structural integrity of continuity (tensile strength) that the sand and gravel reinforcements are incapable of delivering. At the end of the day the cement paste/binder of the prior art are typically reinforced by three reinforcements i.e. sand, gravel and steel.
To articulate how sand and gravel perform as reinforcement of the cement paste/binder of cement-based formulations/mixtures of the prior art, the analogy of a block wall being viewed as a microscopic image of cement-based formulations/mixtures will articulate the concept. The blocks of the wall represent the aggregate and the mortar between the blocks represents the cement paste. Structurally speaking one would never want to see a block wall where the mortar joints between the block were three inches thick, as this would produce a very weak block wall. The mortar is not a strong enough material to be used in thickness over ¾ of an inch. Speaking from the logistics of the application of building a block wall; one would never want to lay a course blocks on three-inch bed of mortar as just after the mason completes placing the block exactly to the level of the set string line, moments later the block would sink to an undesired level even if using a very low slump (dry) mortar. Even when laying block on a ½-inch bed of mortar you can experience the level of a block dropping, that is why procedurally you find a mason laying one course horizontally for as far as the run of the course will go before laying another course on top of a lower course that was just laid, in fear of the next correctly laid block would start to sink or drop down below the prior set string level. With that said, the cement paste/binder needs to be properly reinforced with aggregate (sand and gravel) uniformly to achieve the proper density proportion ratio of the cement paste to aggregate reinforcements.
Reinforcement drawbacks of prior art: The major drawbacks that result from the current cement-based formulations/mixtures embodied by the prior art are as follows:
The reinforcements taught in the prior art in formulating cement-based formulations/mixtures and historically over the last 160+years are aggregate (sand and gravel) and steel. This has been the common practice primarily due to the wide availability of quarried limestone and iron ore. It is a widely held belief and practice that cements based formulations/mixtures must be made with sand, gravel and steel wherein it is an unchallenged basis to any and all formulas of cementitious formulations/mixtures. The use of commonly mined limestone and iron type reinforcements in cement-based mixtures are not ideal, but convenient and when thorough performance analysis is conducted it would seem logical that the analyst would recommend replacement materials be explored. The exacting causes of failure are scientifically well known and documented, but the ability to develop innovative solutions are prevented by the mechanics of tradition and standard issue; “Cement-based mixtures are always made with sand, gravel and steel”. “The world is flat” is somewhat of a comparable oblivious concept of the thought process utilized currently. No industry alternatives have been sought in the replacement of sand and gravel reinforcements in cement-based formulations/mixtures as it is such an unconceivable thought that they need to be replaced or even that they could be replaced. All augmentations to the various cement-based formulations/mixtures for sake of addressing these known problems see the formulators keeping the traditional baseline of the formulations/mixtures inclusive of cement paste, sand, gravel and steel to which they add fiber or some type of an admixture seeking to change the characteristic of the formulations/mixtures. Ultimately this methodology does not realize the necessity of radically seeking the replacement reinforcements of the prior art to obtain ultimate success.
The invention teaches a radical replacement of all the reinforcements of the prior art being achieved. The composition of sand and gravel are largely the same and are only different in size, sand is just smaller gravel. Geologically the widely available mined sand and gravel are predominately limestone (80%) with granite, gabbro and basalt (20%). The sand and gravel vary considerably in the structure of their composition from one grain of sand to another to one piece of gravel to another. Sand and gravel are very porous in and by themselves and are the primary source the porosity of cement-based formulations/mixtures overall. In different cementitious mixtures, the larger the size of the aggregate the more porosity will be created. In mixtures such as a thin paint on type of application of “water stop” (hydraulic cement) no aggregates are used at all, this gives the mixture less porosity and an almost “sealer” like property. Some brands of “water stop” are formulated with small amounts of fine sand, which creates an increased level of porosity over the former. The thinner a mixture is applied the less amount and the finer the sand will have to be utilized. Water stop type cement mixtures cannot be used to pour a 6″ inch thick concrete driveway, as the mixture hasn't the larger aggregate structure and would be brittle and crumble. Concrete mixtures cannot be used to plaster a swimming pool as the aggregates are too large and course to be applied is such a thin application and is far to porous to effectively seal a concrete pool. With that said all cement-based formulations/mixtures are very porous and unstable due to sand and gravel being used as reinforcements.
The porous cement-based formulations/mixtures of the prior art allows moisture (vapor and liquid) in combination atmospheric gases produce acidic moisture, which intrudes/infiltrates in and through the porous nature of cement based formulations/mixtures and results in dissolution of the limestone, causing increasing levels of salt movement within the cement-based formation, which furthers the degradation of the aggregate (sand and gravel) and steel reinforcements and decreased longevity of the cement based formulations/mixtures of the prior art
The invention eliminates these referenced problems and produces a significantly stronger and a longer lasting Structural Insulated Panel System (SIPS), due to the invention's new and unique formulations/mixtures and unique and improved manufacturing processes.
The primary objective of this invention is to provide the building/construction industry with new and unparalleled SIPS with increased performance characteristics of comprehensive, tensile and flexural strengths, reduction of porosity, increased durability, longevity and solves water intrusion concerns. This objective is achieved through the deployment of new and unique cement-based formulations/mixtures taught by the invention for the interior and exterior facings.
Another objective of this invention is to provide SIPS with increased performance characteristics of comprehensive, tensile and flexural strengths, reduction of porosity, increased durability, and longevity. The invention also produces cost saving in the elimination of the purchases and installations of exterior and interior siding and finish effects. This objective is achieved through the deployment of unique and improved manufacturing processes taught by the invention.
Other practical uses and adaptations of this invention should be apparent to those skilled in the art.
The invention teaches three ingredients are needed for the new and unique formulations/mixtures for manufacturing the SIPS:
Cement/ash Paste/binding agent: The use of Portland cement paste as the binding agent/element of the new and unique formulations/mixtures in the invention is desirable, preferred, stable and is an unequalled binding agent in terms of being economical, widely available and durable for centuries. This cement paste/binding agent is by itself has a very dense, low/negligible porosity and does not dissolve, emulsify or transform from one state to another once the process of hydration sets the paste into a hardened crystallized state. The typical batch size taught by the invention requires 125 lbs of Portland cement to make the cement paste for a batch of a mixture for casting.
There are various types of cements that can be used in the various and different new and unique formulations/mixtures of the invention. The various types of cement to be used are substantiated below, as per ASTM C150:
Glass Fiber Reinforcement—Glass is utilized as a much improved and stable aggregate for the new and unique formulations/mixtures of the invention. There are different types and sizes of glass fiber available for agility with formula diversity in servicing different applications. The invention teaches a variety of ratios for the blending of fiber which can be adjusted to meet specific and targeted performance characteristics. The amount of fiber needed for a batch of cement paste from above—see the fiber batch weights below:
Glass Reinforced Woven Mesh—The invention teaches the utilization of glass reinforced woven mesh to further reinforce the new and unique formulations/mixtures for manufacturing the SIPS of the invention. The invention teaches the placement of two layers of the glass reinforced woven mesh in each of the two cement-based structural facing castings. The invention teaches the use of more layers of the glass reinforced woven mesh to further reinforce the new and unique formulations/mixtures for larger SIP panels capable of increase load bearing characteristics as may be required in serving varied applications.
The invention teaches adjustable formulations in batching the three ingredients for casting SIPS of the invention to provide agility in performance characteristic yields. The key to the successes of the invention is there's absolutely NO use of sand, gravel or steel reinforcements taught by the invention. Instead the invention exclusively teaches the use of cement paste, glass fiber and glass reinforcement woven mesh in producing the new and unique formulations/mixtures of the invention.
The invention uniquely teaches the observation and practice of controlling ambient temperature of the production environment of the manufacturing with ranges of between 70° F.-90° F. prior to casting, during casting, and post temperatures during curing of the new and unique formulations/mixtures as an intangible conditioning of the unique and improved manufacturing processes of the invention.
The invention further teaches the elements/compounds/ingredients of the invention formulas are stored at the same temperature ranges. The insulated vacuum molds and all the production tools and equipment used in all the production phases are also stored and utilized at the same increased temperature ranges.
The invention teaches the utilization of insulated vacuum molds which provide efficiencies and effectiveness in the retention of the high temperature releases generated by the inventions new and unique formulations and mixtures in the curing phases. In the curing phase where both the chemical reaction of the cement/pozzolans/water and from the heat that is caused mechanically by the friction of water molecules that hydration produce.
The initial hot water temperatures of 105° F. coupled with the increased temperatures generated during curing along with the insulated vacuum molds that facilitate the retention of these temperatures act like a catalyst in the development of a high temperature accelerated curing of the castings. The invention teaches a methodology of a free high heat baking process with zero energy costs. In this teaching of the invention superior and dramatically increased performance characteristics are yielded. These processes are not taught nor found in the prior art of SIPS and or the teachings of the poured/casted/formed cement based formulations/mixtures and manufacturing processes of the prior art of building/construction industry as a whole
The invention teaches a new and unique high temp moist curing process, which is achieved with the deployment of the “anti-hydration membrane” which under applied vacuum coupled with high temperature produces a beneficial effect of retaining the moisture of the water molecules that normally leave the open un-insulated mold/casting in the hydration/curing phase of the prior art. The invention teaches an improved and more ideal curing conditioning in that the casted formulations/mixtures cure faster and harder due to the retention of an increased moist curing environment over the drier curing environmental conditions taught in the prior art.
These practices are proven to lead to castings with earlier and higher strengths, and the enhanced performance characteristics of comprehensive, flexural (tensile bending), shear, torsion and durability with less porosity, when compared to castings that were produced using cold water, un-improved molds i.e. the manufacturing processes of the prior art.
