non-flammable high-performance plaster-cement compositions with enhanced water durability and therma

专利摘要:
Structural cement panel to resist transversal and cutting loads equivalent to transversal and cutting loads provided by plywood and oriented board, when fixed to the structure for use in cutting walls, floors and roofing systems. The panels offer reduced thermal transmission compared to other structural cement panels. The panels employ one or more layers of a continuous phase resulting from the curing of an aqueous mixture of calcium sulphate alpha hemihydrate, hydraulic cement, load of coated expanded perlite particles, optional additional loads, active pozzolanic and lime. The coated perlite has a particle size of 1-500 microns, 20-150 microns of average diameter and an effective particle density (specific gravity) of less than 0.50 glee. The panels are reinforced with fibers, alkali-resistant glass fibers, for example. The preference panel does not contain any air that is intentionally entrained. A method for improving fire resistance in a building is also disclosed.
公开号:BR112013014175B1
申请号:R112013014175-1
申请日:2011-12-16
公开日:2021-01-19
发明作者:Ashish Dubey；Cesar Chan
申请人:United States Gypsum Company；
IPC主号:

专利说明:

FIELD OF THE INVENTION
[1] This invention relates, in general, to non-flammable high-performance plaster-cement compositions for use in the production of lightweight structural cement panels, hereinafter referred to as SCP panels. Panels are typically used in residential and commercial cutting walls, floor and roof systems. The panels offer a cut-resistant, fire-resistant non-combustible diaphragm, which is water-resistant and thermal-resistant and has axial cutting and carrying capacity. The system, when mounted on the frame, particularly on the steel frame, provides non-flammability, water durability, fire resistance, thermal stability, mold resistance and high specific strength and rigidity. BACKGROUND OF THE INVENTION
[2] This invention relates, in general, to panels applied to molding in residential buildings and other types of light construction. More particularly, the invention relates to panels capable of resisting lateral forces imposed by high wind and earthquake loads in the regions where they are required by building codes. Such panels, commonly known as cut walls or diaphragms, must demonstrate cut resistance as shown in recognized tests, such as ASTM E72-05 (effective 2005).
[3] The cladding panels are measured to determine the load that the panel can withstand within the permitted deviation without fail. The cut rating is generally based on testing three identical 8 X 8 feet (2.44 x 2.44 m) sets, that is, the panels attached to the frame. An edge is fixed in place while a lateral force is applied to a free end of the assembly until the load is no longer transported and the assembly fails. The measured cutting force will vary, depending on the thickness of the panel and the size and spacing of the nails used in the set. For example, a typical set, for example, plywood of nominal 1/2 inch (12.7 mm) thickness secured with 8d nails (see nail description below) for nominal 2 x 4 inch wooden pins ( 50.8 x 101.6 mm) spaced 16 inches (406.4 mm) apart (in the centers), nails being spaced 6 inches (152.4 mm) apart at the perimeter and 12 inches (304.8 mm) distant within the perimeter, it would be expected to show a cutting force of 720 lbs / ft (1072 kg / m) before the failure occurs. (Note, the measured strength will vary as the nail size and spacing are changed, as the ASTM E72 test provides.) This final strength will be reduced by a factor of safety, for example, a factor of three, to establish the strength of cut to the panel.
[4] US Patent No. 6,620,487 to Tonyan et al., Incorporated herein by reference in its entirety, discloses a lightweight, dimensionally stable reinforced structural cement panel (SCP) capable of withstanding cutting loads when attached to the frame equal to or excessive cutting loads provided by plywood or oriented fiber board panels. The panels employ a continuous phase core resulting from the curing of an aqueous mixture of calcium sulphate alpha hemihydrate, hydraulic cement, a pozzolanic active and lime, the continuous phase being reinforced with alkali-resistant glass fibers and containing microspheres of ceramic, or a combination of ceramic microspheres and polymer or being formed from an aqueous mixture having a reactive water-to-powder weight ratio of 0.61 to 0.71 or a combination thereof. At least one outer surface of the panels can include a cured continuous phase reinforced with glass fibers and containing sufficient polymer spheres to improve the fixability or made with a reactive water-to-powder ratio to provide an effect similar to the spheres of polymer, or a combination of these.
[5] US Patent No. 6,241,815 to Bonen, incorporated herein by reference in its entirety, also discloses useful formulations for SCP panels.
[6] US patent 7,445,738 to Dubey, incorporated herein by reference, discloses a multilayer process for the production of structural cement panels (SCP's or SCP panels) and the SCP's produced by such a process. After an initial deposition of loosely distributed fibers, cut fibers or a layer of slurry on the mobile network, the fibers are deposited on the layer of slurry. An embedding device mixes the newly deposited fibers in the slurry, after which additional layers of slurry, and then the cut fibers are added, followed by further incorporation. The process is repeated for each layer of the plate, as desired.
[7] US Patent No. 2009/0011207 A1 to Dubey, incorporated herein by reference, discloses a fast-setting lightweight cement composition for panel or board construction. The cement composition includes 35-60% by weight reactive cement powder (also called Portland cement-based binder), 2-10% by weight expanded and chemically coated perlite filling, 20-40% by weight water, entrained air , for example 1050 vol. %, on a wet basis, entrained air and optional additives such as water reducing agents, set of accelerators and set of chemical retarders. The lightweight cement compositions can also optionally contain secondary fillers 0-25% by weight, for example secondary fillers 10-25% by weight. The typical filling includes one or more of expanded clay, shale aggregate and pumice. The reactive cement powder used is usually composed of both pure Portland cement and a mixture of Portland cement and a suitable pozzolanic material such as fly ash or blast furnace slag. The reactive cement powder can also optionally contain one or more plaster (earth plaster) and high alumina (HAC) cement added in small doses to influence the setting and hydration characteristics of the binder.
[8] US Patent No. 4,304,704 to Billings discloses thermal insulating material containing silicone-treated perlite and a mixture with plaster and cement.
[9] US Patent No. 5,601,919 to Symons discloses a building component, having a core formed of one or more sheets of natural fiber impregnated with a liquid composition, including a thermoplastic resin and a catalyst for fixing the resin and a encapsulation layer, encapsulating the core which may contain a hydraulic binder and water in which the binder is selected from Portland cement or calcium sulphate hemihydrate at 15-65 parts by weight and a filling which may be vermiculite or expanded perlite. The expanded perlite is 0.05 mm to 3 mm of the particle size that is treated with silicone to make it hydrophobic.
[10] There is still a need for improved panels that can meet the required cutting rate in certain locations and that exceed the capacity of the currently used wood-based panels, as well as the current plaster-cement-based structural cement panels, providing a non-flammable panel with the same cut resistance at the lower weight of the panel which also improved water durability and thermal resistance. SUMMARY OF THE INVENTION
[11] The panels of the invention can generally be described as made of gypsum-cement compositions reinforced with glass fibers and, with the addition of coated perlite particles coated in place of hollow ceramic microspheres or polymers of the prior art. In addition, the panels of the invention are light in weight compared to hydraulic cement panels. The panels will satisfy the performance requirements listed above and can be distinguished from other prior art compositions discussed above that contain similar components, but are not able to achieve all the desired performance properties of the present structural cement panels.
[12] The present invention relates to a system of light residential and commercial constructions, including a lightweight SCP panel. This panel is made of a mixture of inorganic binder and light fillers that are intended to be used in a system in which all elements pass ASTM E-136.
[13] SCP slurry compositions of the present invention specifically include hemihydrate calcium sulfate (plaster), a hydraulic cement such as Portland cement, silica fume, lime, fine expanded perlite particles that are coated to be hydrophobic, superplasticizer and tartaric acid. In these compositions, fine expanded perlite is used both as a partial and total replacement for filling the hollow ceramic microsphere used in previous SCP formulations to provide lighter weight, reduced moisture absorption, better moisture durability and enhanced thermal stability, while maintaining the same levels of mechanical performance properties, such as long-term durability, resistance to freezing and dimensional stability, as previous structural cement panels.
[14] The expanded pearlite in the present invention has a particle size range of 1 to 150 microns (micrometers) and is treated with a coating that makes the coated pearlite hydrophobic. At the partial substitution level, this perlite displaces up to half the volume of the microsphere, and at the complete substitution level, the perlite displaces the entire fraction of the microsphere.
[15] The present system having a horizontal cut diaphragm in the frame, typically light gauge metal frame is also normally durable to water. Preferably, the load carrying capacity of the horizontal cut diaphragm of a system of the present invention will not be decreased by more than 25% (more preferably it will not be decreased by more than 20%) when exposed to water in a test where a surface 2-inch (51 mm) water is held on 3/4 inches of thick SCP panels (19 mm) attached to a 10-foot by 20-foot (3,048 -,096-meter) metal frame for a period of 24 hours. In this test, the 2 inch (51 mm) surface is maintained by checking and replenishing the water, at 15 minute intervals.
[16] Preferably, the system of the present invention will not absorb more than 0.7 pounds per square foot (.0034 grams per square meter) of water when exposed to water in a test in which a 2 inch (51) water surface mm) of water is kept on 3/4 inches of thick SCP panels (19 mm) attached to a 10-foot by 20-foot metal frame (3,048 from 6,096 meters) for a period of 24 hours. In this test, the 2 inch (51 mm) surface is maintained by checking and replenishing the water, at 15 minute intervals.
[17] Also, combining non-flammable SCP panels with the metal frame results in an entire system that resists swelling due to moisture. Preferably, in the system of the present invention a 10-foot-wide by 20-foot-long and 34-inch-thick diaphragm of SCP panels attached to a 10-foot-by-20-foot metal frame (3,048 by 6,096 m) will not swell more than 5% when exposed to a 2 inch (51 mm) water surface held on the SCP panels attached to the metal frame for a period of 24 hours. In this test, the 2 inch (51 mm) surface is maintained by checking and replenishing the water, at 15 minute intervals.
[18] The system of the present invention can employ single-layer or multilayer SCP panels. In the multilayer SCP panel, the layers can be the same or different. For example, the SCP panel may have an inner layer of a continuous phase and at least one outer layer of a continuous phase on each opposite side of the inner layer, where at least one outer layer on each opposite side of the inner layer has a percentage higher than glass fibers than the inner layer. This has the ability to harden, strengthen and harden the panel.
[19] The current system is lighter than the current structural cement panels, retaining the same shear force. Thus, a present system having a SCP panel with 3/4 inch (19 mm) horizontal diaphragm in the metal frame facilitates the efficient use of the construction volume for a given construction footprint to allow the maximization of the constriction volume for the given construction footprint. Thus, the present system can allow more floor and ceiling height or even a greater number of floors in zoning areas with constrained height constructions.
[20] The lightweight nature of this system normally avoids the dead load associated with poured metal concrete systems. Less inoperative load also allows the construction of structures of comparable size on less stable soil having relatively low bearing capacity.
[21] In addition, adding fire resistant plasterboard, such as Type X plasterboard or other sound attenuating material, can improve the sound insulation provided by SCP floors or roofs. This can especially reduce the IIC (impact noise). Typical materials to add include underfloor panels (making a floor that is non-flammable from the bottom), FIBEROCK® brand interior panels (available from US Gypsum Corporation, Chicago, Illinois) to make a non-flammable floor), LEVELROCK® brand underfloor (available from US Gypsum Corporation, Chicago, Illinois) (to make a non-flammable floor), or an acoustic plaster (to make a non-flammable floor). To receive the designation "Type X" according to ASTM C 36, a plasterboard product must be able to achieve a rate of not less than one hour of fire resistance for a 5/8 "(16 mm) board or a fire resistance rate of 3/4 hours for a 1/2 "(12.7 mm) plate, applied in a single layer, nailed to each face of the load-bearing wooden frame members, when tested in compliance with the requirements of ASTM E 119, Methods of Fire Test of Building Constructions and Materials. An acoustic ceiling can also be applied to the bottom of the floor joists. The ceiling panels are attached to resilient channels or a suspension grid.
[22] As the thickness of the plate affects its physical and mechanical properties, for example, weight, load carrying capacity, carrying capacity and the like, the desired properties vary according to the thickness of the plate. In general, the thickness of a panel of the invention can be within the range of about 0.125 to 4.0 inches (3.2 to 101, 6mm), with a preferred thickness in the range of 0.25 to 2.0 inches (6, 4 to 50.8mm) and an even more preferred thickness in the range of about 0.40 to 1.0 inches (10.6 to 25.4mm). Thus, for example, the desired properties that a cut panel calculated with a nominal thickness of 0.75 inches (19.1 mm) should include the following.
[23] When used as sub-floors in floor covering applications by ICC-ES Acceptance Criteria AC-318, a typical panel of the present invention when tested according to ASTM E 661 over a 16, 20 or 24 inch span (406, 508 or 610 mm), the center has a final load capacity greater than 400 lbs (182 kg) before impact and a final load capacity greater than 400 lbs (182 kg) after impact. The maximum deflection should be less than 0.125 inches (3.2 mm), before and after impact with a 200 lb (90.9 kg) load.
[24] When used as single floors in floor covering applications by ICC-ES AC 318, a typical panel of the present invention, when tested according to ASTM E 661 over a 16, 20 or 24 inch span (406, 508 or 610 mm), the center has a final load capacity greater than 550 lbs (250 kg) before impact and a final load capacity greater than 400 lbs (182 kg) after impact. The maximum deflection before and after impact with a load of 200 lb (90.9 kg) should be less than 0.078 inches (1.98 mm), 0.094 inches (2.39 mm) and 0.108 inches (2.74 mm) over 16, 20 and 24 inch extensions (406, 508, and 610mm) respectively.
[25] When used for roof cladding applications by ICC-ES AC 318, a typical panel of the invention, when tested according to ASTM E 661 over a length of 16, 20 or 24 inches (406, 508 or 610 mm) , in the center has a final load capacity greater than 400 lbs (182 kg) before impact and a final load capacity greater than 300 lbs (136 kg) after impact. The maximum deflection before and after impact with a load of 200 lb (90.9 kg) should be less than 0.438 inches (11.1 mm.), 0.469 inches (11.9 mm), 0.500 inches (12.7 mm) and 0.500 inches (12.7 mm.) over 16, 20 24 and 32 inch extensions (406, 508, 610 and 813 mm) respectively.
[26] When used for ICC-ES AC 318 floor covering applications, a typical panel of the invention, when tested according to ASTM E 330, must have a uniform final load capacity greater than 330 lpq (pounds per square foot) ) (15.8 kPA) and flex more than (extension / 360) at a permissible load of 100 lpq (4.8 kPa). These requirements apply to both dry test conditions and wet test conditions (after 7 days of continuous moisture and then testing while wet).
[27] When used for roof cladding applications by ICC-ES AC 318, the panels of the invention, when tested according to ASTM E 330, must have a uniform final load capacity greater than 150 lpq (7.2 kPa) and flex more than (extension / 240) to a permissible load of 35 lpq. (1.7 kPa) These requirements apply to both dry test conditions and wet test conditions (after seven days of continuous moisture and then wet tested).
[28] Panels of the invention, when tested according to PS2-04, Section 7.4, must demonstrate a minimum lateral locking load of 210 lbs (95.5 kg.) In the dry state and 160 lbs (72.2 kg) ) after seven days of continuous humidity and testing while wet.
[29] Panels of the invention, when tested according to ASTM D 1037, Sections 47-53, must demonstrate a minimum closing shrinkage load of 20 lbs (9.1 kg) in the dry state and 15 lbs (6, 8 kg) after seven days of continuous humidity and testing while wet.
[30] Panels of the invention, when tested according to ASTM D 1037, Sections 54-60, must demonstrate a minimum closing tensile load of 200 lbs (90.9 kg.) In the dry state and 150 lbs (68 , 2 kg) after seven days of continuous humidity and testing while wet.
[31] A panel of 4 x 8 feet, 3/4 inches thick (1.22 x 2.44 m, 19.1 mm thick) typically weighs no more than 156 lbs (71 kg) and, preferably, not more than 144 lbs (65.5 kg).
[32] Typical compositions for panel modalities of the present invention that achieve the combination of low density, flexural strength and fixability / cutability comprises the inorganic binder (examples - plaster-cement, Portland cement or other hydraulic cements) having, distributed by total thickness of the panel, selected glass fibers, light fillings of coated expanded perlite and superplasticizer / high water extension reducing adjuvants (examples - polyynapphalene sulfonates, polyacrylates, etc.). Hollow glass or ceramic microspheres can optionally be used with coated expanded perlite, although the use of coated expanded perlite particles is preferred.
[33] The panels can be single layer panels or multilayer panels. A typical panel is made of a mixture of water and inorganic binder with selected glass fibers, light ceramic microspheres and superplasticizer throughout the mixture. Other additives such as acceleration and retardation of adjuvants, viscosity control additives can optionally be added to the mixture to meet the demands of the manufacturing process involved.
[34] A single layer or multilayer panel can also be provided with an interlaced structure sheet, for example, fiberglass mesh, if desired.
[35] In modalities having multiple layers (two or more), the composition of the layers can be the same or different. For example, a multilayer panel structure can be created to contain at least one outer layer having a fixability and cutability or notch and fit. This is provided using a higher rate of a water reactive powder (defined below) in the production of the outer layer (s) relative to the core of the panel. A small thickness of the skin, together with a small dosage of the polymer content, can improve the fixation capacity without necessarily failing the non-flammability test. Of course, high doses of the polymer content would lead to product failure in the non-flammability test.
[36] Glass fibers can be used alone or in combination with other types of non-flammable fibers, such as steel fibers.
[37] As discussed earlier, there is a need for a light, non-flammable cut wall, floor and roof systems to replace wooden or metal frames, coated with current OSB plywood panels or structural cement panels.
[38] Another advantage is that the lighter weight structural panels of the present invention can also achieve a fire resistance rate of 2 hours according to ASTM E-119, using the SCP panel, for example% inch panel (19 mm) or 1 inch (25.4 mm) SCP in the metal frame with Type X plasterboard on the side of the metal frame opposite the side on which the SCP panel is on, while achieving improved thermal resistance compared to current SCP panels.
[39] The present invention achieves the combination of low density and malleability required for manipulating the panel and fastening capacity with properties of good fluidity, water durability and improved thermal properties using uniformly coated expanded perlite particles distributed over the total thickness of the panel . This provided a panel with a lower rate of water reactive dust (defined below) that allows for significant weight reduction in the resulting panel weight and improved strength compared to panels made with hollow ceramic microspheres or combinations of ceramic microspheres and spheres of polymer. The use of coated expanded perlite also makes a panel that can readily meet the non-flammability test, essentially eliminating a source of unburned or organic carbon in the light filler panel such as ceramic microspheres or polymer spheres.
[40] For use in construction, improved SCP panels must meet building code standards for cut resistance, load capacity, water-induced expansion, water durability, freeze and thaw durability, long-term durability and strength combustion, as measured by recognized tests, such as ASTM E72, ASTM E 661, ASTM C 1704 and ASTM C 1185 or equivalent, as applied to structural plywood sheets. SCP panels are also tested under ASTM E-136 for non-flammability - plywood does not meet this test.
[41] The improved SCP panel must be able to be cut with the circular saw used to cut wood.
[42] The improved SCP panel must be dimensionally stable when exposed to water. It should expand less than 0.1% in both the machine and cross machine directions, as measured by ASTM C 1185, and the thickness expansion should be less than 3%, as measured by ASTM D 1037, Method B.
[43] The water absorption of the panels of the present invention should not exceed 15% by weight when tested within 28 days after manufacture in accordance with ASTM C 1704.
[44] When tested according to the ASTM C 1704 method, wet conditioned samples of the panels of the invention must retain a minimum of 70% of the maximum load capacity and maximum deflection compared to a dry control panel sample. Wet conditioning of the samples is carried out by submerging the samples in water at 70 + 5 ° F (21+ 3 ° C) for 48 + 2 hours and then drying the samples until no free moisture is visible on the sample surface immediately before to start the test.
[45] The improved SCP panel of the invention must retain a minimum of 75% of the control force value after 50 freeze-thaw cycles, as determined, by using the section applicable to the freeze-thaw panel under ASTM C 1185.
[46] The panels of the invention must demonstrate a minimum retention of 75% of the maximum load capacity and maximum deflection, when tested by ASTM C 1185, under the section applicable to long-term durability, with conditioning started within 28 days. after manufacture.
[47] The improved SCP panel must provide a bondable substrate for exterior finish systems.
[48] The improved SCP panel must be non-flammable as determined by ASTM E136, without the need for flammable components of prior art microsphere fillers.
[49] The improved SCP panel of the invention must achieve a flame spread of 0 and a maximum developed smoke of 5, as determined by the method of ASTM E 84.
[50] When used for flooring applications in 16, 20 or 24 inch (406, 508 or 610 mm) extensions in the center, the moment capacity of SCP panels, as determined by the ASTM C 1704 method, is at least 1,450 lbf-inch / foot wide (537 Nm / m wide) in both machine and cross-machine directions in the dry condition, and is at least 1,015 lbf-inch / foot wide (376 N-m / m width) in both machine and cross-machine directions in the wet condition. These current capacity values are in accordance with the requirements as set out in the Acceptance Criterion ICC-ES AC-318 and the ASTM C-1705 Standard. The wet conditioning of the panels is described in paragraph 44, page 10. The flexural stiffness of the dry samples should be 223,000 lbf-inch2 / foot wide (2,100 N-m2 / m wide) in both machine and machine directions - crossed as determined under the method in ASTM C 1704.
[51] When used for roof cladding applications in 16, 20 or 24 inch (406, 508 or 610 mm) extensions in the center, the moment capacity of SCP panels, as determined by the ASTM C 1704 method, is at less than 1,007 lbf-inch / foot wide (3,743 Nm / m wide) in both machine and cross-machine directions in the dry condition, and is at least 705 lbf-inch2 / foot wide (261 N- m / m wide) in both machine and cross machine directions in the wet condition. The values are in accordance with the minimum values of the current capacity as established in the Acceptance Criterion ICC-ES AC-318. The wet conditioning of the panels is described in paragraph [0044]. The flexural stiffness of dry samples should be 129,051 lbf- inch2 / foot wide (1,215 N-m2 / m wide) in both machine and cross-machine directions as determined under the method in ASTM C 1704. In a 32-inch (813 mm) extension in the center, the panel should display a dry moment capacity of 1,450 lbf-inch / foot wide (537 Nm / m wide), a wet moment capacity of 1,015 lbf-inch / foot wide (376 Nm / m wide) and dry flexural stiffness of 223,000 lbf-inch2 / foot wide (2,100 N-m2 / m wide).
[52] For roof cladding applications, the panels of the invention must be tested for 25 cycles by ASTM C 1185, Section 15 at least 28 days after manufacture. Upon completion of the radiant heat portion of the first test cycle, the panel must have a minimum retention of 75% of the maximum load and maximum deflection values established by flexural tests compared to samples from the control panel.
[53] The panels of the invention must also exhibit a mold strength value of 10 when tested in accordance with ASTM D 3273 and a mold strength value of 1 or less when tested in accordance with ASTM G 21. BRIEF DESCRIPTION OF THE FIGURES
[54] FIG. 1 is a perspective view of a single layer SCP panel of the present invention.
[55] FIG. 2 is a fragmentary cross-section of a multilayer SCP panel system of the present invention.
[56] FIG. 3 is a diagrammatic elevational view of an apparatus that is suitable for performing the process for producing the SCP panel of the present invention.
[57] FIG. 4 is a perspective view of a slurry feeding station of the type used in the production process of the SCP panel of the present invention.
[58] FIG. 5 is a fragmentary aerial plan view of an embedding device suitable for use with the process for producing the SCP panel of the present invention.
[59] FIG. 6 is a bar graph of the abatement of formulations prepared using ceramic microspheres compared to partial and total replacement of the microspheres with the expanded perlite of the invention.
[60] FIG. 7 is a bar graph of the density of the slurry of formulations prepared using ceramic microspheres and partial and total replacement of the microspheres with the expanded perlite of the invention.
[61] FIG. 8 is an initial set of bar graphs of formulations prepared using ceramic microspheres and partial and total replacement of the microspheres with the expanded perlite of the invention.
[62] FIG. 9 is a 28-day compressive strength bar graph of formulations prepared with ceramic microspheres and formulations with partial and total replacement of the microspheres with the expanded perlite of the invention.
[63] FIG. 10 is a set of bar graphs of the slump versus time and slump as a percentage of the initial slump versus time value for formulations containing microspheres and the expanded perlite of the invention as a total replacement for microspheres in varying dosages of tartaric acid.
[64] FIG. 11 is a set of bar graphs for flexural performance in 14 days of panels made using ceramic microspheres and partial and total replacement of the ceramic microspheres with the expanded perlite of the invention.
[65] FIG. 12 is a set of bar graphs for flexural performance in 28 days of panels made using ceramic microspheres and partial and total replacement of the ceramic microspheres with the expanded perlite of the invention.
[66] FIG. 13 is a bar graph of MOR after 48 hours immersion of panels made using ceramic microspheres and partial and total replacement of the ceramic microspheres with the expanded perlite of the invention.
[67] FIG. 14 is a bar graph of AMOE after 48 hours immersion of panels made using ceramic microspheres and partial and total replacement of the ceramic microspheres with the expanded perlite of the invention.
[68] FIG. 15 is a bar graph of the Dry Lateral Fixture Resistance for panel samples made using ceramic microspheres and partial and total replacement of the ceramic microspheres with the expanded perlite of the invention.
[69] FIG. 16 is a bar graph of the wet lateral fixation resistance for panel samples made using ceramic microspheres and partial and total replacement of the ceramic microspheres with the expanded perlite of the invention.
[70] FIG. 17 is a bar graph of the sample carrying capacity of panels made using ceramic microspheres and partial and total replacement of the ceramic microspheres with the expanded perlite of the invention.
[71] FIG. 18 is a bar graph for a permanent set of panels made using ceramic microspheres and partial and total replacement of the ceramic microspheres with the expanded perlite of the invention.
[72] FIG. 19 is a bar graph for water absorption for panel samples made using ceramic microspheres and partial and total replacement of the ceramic microspheres with the expanded perlite of the invention.
[73] FIG. 20 is a bar graph for linear expansion for panel samples made using ceramic microspheres and partial and total replacement of the ceramic microspheres with the expanded perlite of the invention.
[74] FIG. 21 is a bar graph for temperature-time curves for panel samples made using ceramic microspheres and partial and total replacement of the ceramic microspheres with the expanded perlite of the invention exposed to 500 ° C.
[75] FIG. 22 is a bar graph for temperature-time curves for panels made using ceramic microspheres and partial and total replacement of the ceramic microspheres with the expanded perlite of the invention tested in a small-scale horizontal furnace.
[76] FIG. 23 is a graph of the slump in inches versus time for cement compositions of the invention containing coated perlite compared to identical compositions containing uncoated perlite.
[77] FIG. 24 is a density versus time graph for cement compositions of the invention containing coated perlite compared to identical compositions containing uncoated perlite.
[78] FIG. 25 is a slump bar graph in inches versus time for compositions of the invention containing ceramic microspheres compared to the coated perlite of the invention made with similar dosages of superplasticizer.
[79] FIG. 26 is a photograph of the lightweight coated expanded pearlite used in the panel of the invention.
[80] FIG. 27 is a photograph of a crushed perlite particle showing the honeycomb microstructure of the perlite of the invention. DETAILED DESCRIPTION OF THE INVENTION
[81] FIG. 1 is a schematic perspective view of a single layer SCP panel 20 of the present invention. The primary starting materials used to make such SCP panels are inorganic binder, for example, calcium sulfate alpha hemihydrate, hydraulic cement and pozzolanic materials, light-filled coated expanded pearlite and optional extras, ceramic microspheres or glass microspheres, as well as superplasticizer, for example, polyphthalene sulfonates and / or polyacrylates, water and optional additives.
[82] If desired, the panel can have a single layer, as shown in FIG. 1. However, the panel is usually made by a process that applies multiple layers which, depending on how the layers are applied and cured, as well as whether the layers have the same or different compositions, may or may not, in the final product of the panel , keep separate layers. A multilayer structure of a panel 21 having layers, 22, 24, 26 and 28 is shown in FIG. 2. In the multilayer structure, the composition of the layers can be the same or different. The typical thickness of the layer (s) varies between about 1/32 to 1.0 inches (about 0.75 to 25.4 mm). Where only one outer layer is used, it will normally be less than 3/8 of the total thickness of the panel. Calcium Sulfate Hemihydrate
[83] Calcium sulfate hemihydrate, which can be used in panels of the invention, is made from gypsum ore, a naturally occurring mineral, (calcium sulfate dihydrate CaSO4 ^ 2H2O). Unless otherwise indicated, "gypsum" will refer to the dihydrated form of calcium sulfate. After being extracted, the raw gypsum is thermally processed to form a configurable calcium sulfate, which can be anhydrous, but more typically it is the hemihydrate, CaSO4 ^ 1 / 2H2O. For purposes of family use, configurable calcium sulfate reacts with water to solidify, forming the dihydrate (gypsum). The hemihydrate has two recognized morphologies called alpha hemihydrate and beta hemihydrate. These are selected for various applications based on their physical properties and cost. Both forms react with water to form calcium sulfate dihydrate. After hydration, hemihydrate alpha is characterized by giving rise to rectangular gypsum crystals, while beta hemihydrate is characterized by hydrating to produce gypsum needle-shaped crystals, usually with a high definition rate. In the present invention either or both alpha or beta forms can be used depending on the desired mechanical performance. Beta hemihydrate forms less dense microstructures and is preferred for low density products. Alpha hemihydrate forms denser microstructures, having greater strength and density than those formed by beta hemihydrate. Thus, alpha hemihydrate could be replaced with beta hemihydrate to increase strength and density, or they could be combined to adjust properties.
[84] A typical embodiment for the inorganic binder used to make the panels of the present invention comprises hydraulic cement, such as Portland cement, high alumina cement, pozzolan mixed with Portland cement or mixtures thereof.
[85] Another typical embodiment for the inorganic binder used to make the panels of the present invention comprises a combination containing calcium sulfate alpha hemihydrate, hydraulic cement, pozzolan and lime. Hydraulic Cement
[86] ASTM defines "hydraulic cement" as follows: cement that defines and hardens by chemical interaction with water and is capable of doing so under water. There are several types of hydraulic cements used in the construction and construction industries. Examples of hydraulic cements include Portland cement, slag cements such as blast furnace slag cement and super-sulfated cements, calcium sulfoaluminate cement, high alumina cement, expansive cements, white cement and fast-setting and hardening cements. Although calcium sulfate hemihydrate settles and hardens by chemical interaction with water, it is not included in the broad definition of hydraulic cements in the context of the present invention. All of the hydraulic cements mentioned above can be used to make the panels of the invention.
[87] The most popular and widely used family of closely related hydraulic cements is known as Portland cement. ASTM C 150 defines "Portland cement" as a hydraulic cement produced by spraying clinker, consisting essentially of hydraulic calcium silicates, usually containing one or more of the forms of calcium sulfate as an integral complement. For the manufacture of Portland cement, an intimate mixture of limestone, clay and clay is ignited in an oven to produce clinker, which is then further processed. As a result, the following four main phases of Portland cement are produced: tricalcium silicate (3CaO ^ SiO2, also referred to as C3S), dicalcium silicate (2CaO ^ SiO2, called C2S), tricalcium aluminate (3CaO ^ Al2Oa or C3A), and aluminoferrite tetracalcium (4CaO ^ A ^ O3 ^ Fe2O3 or C4AF). Other compounds present in small amounts in Portland cement include calcium sulfate and other double salts of alkaline sulfates, calcium oxide and magnesium oxide. Of the several recognized grades of Portland cement, Portland cement Type III (ASTM classification) is preferred to produce the panels of the invention, due to its fineness, it has been shown to provide the greatest strength. The other recognized classes of hydraulic cements including slag cements such as blast furnace slag cement and super-sulfated cements, calcium sulfoaluminate cement, high alumina cement, expansive cements, white cement, fast-setting and hardening cements such as regulated laying cement and VHE cement and the other types of Portland cement can also be used successfully to produce the panels of the present invention. Slag cements and calcium sulfoaluminate cement have low alkalinity and are also suitable for producing the panels of the present invention.
[88] It should be understood that, as used here, hydraulic cement does not include gypsum, which does not gain resistance under water, although normally some gypsum is included in Portland cement.
[89] When cement slabs are to be produced, Portland cement will normally be in the form of very fine particles such that the surface area of the particle is greater than 4,000 cm2 / gram and typically between 5,000 to 6,000 cm2 / gram as measured by the Blaine surface area method (ASTM C 204). Of the several recognized classes of Portland cement, Type III ASTM Portland cement is usually more preferred in cement reactive powder than cement compositions, due to its relatively faster reactivity and high early strength development.
[90] In the present invention, the need to use Portland Type III cement is minimized and the relatively rapid development of early strength period can be achieved using other cements instead of Portland Type III cement. The other recognized types of cements that can be used to replace or complement Portland Type III cement in the composition of the invention include Portland Type I cement or other hydraulic cements, including white cement, slag cements such as high-grade slag cement. furnace, mixed pozzolan cements, expansive cements, sulfoaluminate cements and oil cements. Fibers
[91] Glass fibers are commonly used as an insulating material, but they have also been used as reinforcement materials with various matrices. Fibers provide themselves with tensile strength to materials that may be subject to fragile failure. The fibers can break when loaded, but the usual way of failure of compounds containing glass fibers is due to degradation and deficiency in the connection between the fibers and the material of the continuous phase. Thus, such bonds are important if the reinforcing fibers are to maintain the ability to increase ductility and strengthen the compound over time. Typically used are alkali-resistant glass fibers (AR glass fibers), for example, Nippon Eletric Glass (NEG) 350 Y. It has been found that such fibers provide superior bond strength to the matrix and are therefore preferred for invention panels.
[92] Glass fibers are typically monofilaments that have a diameter of about 5 to 25 microns (micrometers), usually a diameter of about 10 to 15 microns (micrometers). The filaments are usually combined into 100 strands of filaments, which can be grouped into strands, which contain about 50 strands. The strands or wicks will generally be cut into appropriate filaments and bundles of filaments, for example, about 0.25 to 3 inches (6.3 to 76 mm) in length, usually 0.25 to 2 inches (6.3 to 50 mm) or 1 to 2 inches (25 or 50 mm) in length. The fibers are randomly oriented, providing mechanical isotropic behavior in the plane of the panel.
[93] It is also possible to include other non-inflatable fibers in the panels of the invention, for example, steel fibers are also potential additives.
[94] To promote non-flammability, a modality may have an absence of polymer fibers. Pozzolanic Materials
[95] As already mentioned, most Portland cements and other hydraulic cements produce lime during hydration (curing). It is desirable to react with lime to reduce the attack on the fiberglass. It is also known that when hemium-hydrated calcium sulfate is present, it reacts with the tricalcium aluminate in the cement to form the etringite, which can result in undesirable cracking of the cured product. This is often referred to in the art as "sulfate attack". Such reactions can be prevented by adding "pozzolanic" materials, which are defined in ASTM C618-97 as “. . . siliceous or silica and aluminous materials that, in themselves, have little or no cement value, but, in finely divided form and in the presence of moisture, will react chemically with calcium hydroxide at normal temperatures to form compounds having cement properties. ” A pozzolanic material used frequently is silica fume, finely divided into amorphous silica, which is the product of the manufacture of silicon metal and ferro-silicon alloys. Characteristically, it has a high silica content and a low alumina content. Various natural and synthetic materials have been reported to have pozzolanic properties, including pumice, pearlite, diatomaceous earth, tuff, volcanic ash, metakaolin, microsilica, blast furnace slag and fly ash. While active silica is a particularly suitable pozzolan for use in the panels of the invention, other pozzolanic materials can be used. In contrast to silica fume, metakaolin, granulated blast earth slag, and pulverized fly ash have much less silica content and large amounts of alumina, but can be effective pozzolanic materials. When silica fume is used, it will constitute about 5 to 30% by weight, preferably 10 to 15% by weight, of the reactive powders (ie, hydraulic cement, calcium sulfate alpha hemihydrate, silica fume and lime). If other pozzolans are replaced, the amounts used will be chosen to provide chemical performance similar to silica fume.
[96] The reactive cement powder mixture of the cementitious composition may contain high concentrations of mineral additives, such as pozzolanic materials and / or non-pozzolanic aggregates, for example, calcium carbonate, mica, talc, etc.
[97] ASTM C618-97 defines pozzolanic materials as "siliceous or silica and aluminous materials that have, in themselves, little or no cement value, but, in finely divided form and in the presence of moisture, will react chemically with hydroxide of calcium at normal temperatures to form compounds having cementitious properties. ” Various natural and synthetic materials have been referred to as pozzolanic materials, possessing pozzolanic properties.Some examples of pozzolanic materials include pumice, diatomaceous earth, silica fume, tuff, volcanic ash, rice husk, metakaolin, high-grained earth slag oven and fly ash All these pozzolanic materials can be used individually or in combination as part of the reactive cement powder of the invention.
[98] Pumice used as a pozzolanic mineral additive is an unhydrated form and falls within the ASTM C618-97 definition of pozzolanic materials as “siliceous or silica and aluminous materials that have little or no value in themselves. cement, but, in finely divided form and in the presence of moisture, it will chemically react with calcium hydroxide at normal temperatures to form compounds having cement properties. ”
[99] Fly ash is the preferred pozzolan in the mixture of the reactive cement powder of the invention. Fly ash containing a high content of calcium oxide and calcium aluminate (such as standard ASTM C618 Class C fly ash) is preferred, as explained below. Other mineral additives such as calcium carbonate, clays and crushed mica can also be included.
[100] Fly ash is a by-product of fine powder, formed from the combustion of coal. Power plant utility boilers burning pulverized coal produce most commercially available fly ash. These fly ash consist mainly of glassy spherical particles, as well as residues of hematite and magnetite, animal charcoal and some crystalline phases formed during cooling. The structure, composition and properties of fly ash particles depend on the structure and composition of coal and the combustion processes by which fly ash is formed. The ASTM C618 standard recognizes two main classes of fly ash for use in concrete - Class C and Class F. These two classes of fly ash are derived from different types of coals that are a result of differences in the processes of coal formation that occur during geological time periods. Class F fly ash is usually produced from the burning of anthracite or bituminous coal, whereas Class C fly ash is normally produced from lignite or sub-bituminous coal.
[101] The ASTM C618 standard differentiates fly ash from Class F and Class C primarily according to its pozzolanic properties. In this sense, in the ASTM C618 standard, the biggest difference in specification between the fly ash of Class F and the fly ash of Class C is the lower limit of SiO2 + Al2O3 + Fe2O3 in the composition. The minimum limit of SiO2 + Al2O3 + Fe2O3 for Class F ash is 70% and for Class C ash it is 50%. Thus, Class F fly ash is more pozzolanic than Class C fly ash. Although not explicitly recognized in the ASTM C618 standard, Class C fly ash usually contains a high calcium oxide content. The presence of a high calcium oxide content causes Class C ash to have cement properties, leading to the formation of hydrated calcium silicate and calcium aluminate when mixed with water. As will be seen in the examples below, Class C fly ash has been found to provide superior results, specifically in preferred formulations where high alumina cement and gypsum are not used. Chemically Coated Expanded Perlite
[102] Light panels used in systems of the present invention typically have a density of 50 to 100 pounds per cubic foot (0.80 to 1.60 g / cc), preferably 65 to 85 pounds per cubic foot (1.04 at 1.36 g / cc), more preferably from 70 to 80 pounds per cubic foot (1.12 to 1.28 g / cc). In contrast, typical Portland cement-based panels without wood fiber will have densities in the range 95 to 110 lpc (1.52 to 1.76 g / cc), while Portland cement-based panels with wood fibers will be the same as SCP (about 65 to 85 lpc (1.04 to 1, 36 g / cc)).
[103] To help achieve these low densities, the panels are supplied with light coated particles of coated expanded perlite. The expanded perlite filling is about 2-10% by weight, about 7.5-40% by volume of the cementitious slurry (on a wet basis). The expanded perlite filler particles typically have an average particle diameter between 20-500 microns or 20 to 250 microns, preferably between 20-150 microns, more preferably between 20-90 microns and, even more preferably, between 20-60 microns. microns. Also, the expanded perlite filler particles have an effective particle density (specific gravity) preferably less than 0.50 g / cc, more preferably less than 0.40 g / cc and, even more preferably, less than 0.30 g / cc.
[104] The expanded perlite particles serve an important purpose in the panels of the invention, which, otherwise, would be heavier than desirable for the construction of panels.
[105] The expanded perlite particles have a hydrophobic coating. Usually, the expanded perlite particles are chemically treated with one or more silanes, siloxane or silicone coating or a mixture thereof.
[106] A scanning electron micrograph of the coated perlite particles of the invention is shown in Figure 26. The perlite particles of this invention are not completely hollow, but have an internal honeycomb microstructure, as shown in the electron micrograph of scan in Figure 27. The honeycomb-shaped microstructure is essentially created by thin walls that run randomly in the hollow space of the perlite particle. The various walls present in the pearlite particle cross each other at random and thus compartmentalize the overall volume of the particle into small sections. This honeycomb-shaped microstructure offers several benefits for the perlite particle and for the cementitious compositions of the invention. Important benefits provided by the honeycomb microstructure include: [107] Water absorption of the reduced particle: as the particle is internally subdivided into small sections, due to its honeycomb construction, the migration of water from a section to another within the particle is interrupted by the inner walls. Consequently, the absolute water absorption of the perlite particle is significantly reduced. Perlite particles with low water absorption are beneficial in the present invention, as they help to reduce the water demand of the cementitious slurry and increase the mechanical performance and durability of the finished product. [108] Increased particle stiffness and strength: the honeycomb-shaped walls within the particle help to substantially increase the particle's stiffness and strength. As a result, perlite particles are less prone to damage during manufacturing and loading transport at various stages of their life cycle. In addition, the relatively high stiffness and strength of the particle is also extremely beneficial in various mixing operations for the preparation of cement slurries where the particles are subjected to extensive cutting and crushing actions. The high stiffness and strength of the particle helps to maintain the integrity of the particle under aggressive mixing conditions.
[107] As a result, perlite particles are able to maintain their light weight and low water absorption properties when used in the manufacture of cement panel products. It should be noted that, with the crushing and breaking of the perlite particles, the particle density increases significantly, thus decreasing the light weight and low water absorption
[108] Perlite can be coated with silicone, silane or siloxane coatings, such as dimethyl, dimethylchlorosilane or polydimethylsiloxane silicone. If desired, coatings of titanates or zirconates can be employed. Typically, coatings are supplied in an amount of 0.01 to 3%, more usually 0.01 to 2%, by weight of the uncoated weight of the perlite particle. The coatings on the pearlite are typically a cross-linked hydrophobic film, forming compounds. Typical silicones are organo-functional silanes, having the general formula R-SiX3 in which R is selected from the group consisting of alkoxy and acetoxy such as acrylate, methacrylate, glycidoxy, epoxy propoxy, epoxy cyclohexyl and vinyl, and X is selected from the group consisting of halogen, alkoxy and acetoxy.
[109] In addition, the coated particle size of coated expanded perlite allows the formation of a water-tight, effective closed cell particle structure with the application of the chemical coating. The use of the selected coated expanded perlite filler is important to allow the preparation of workable and processable cement slurries at low water usage rates. Lower amounts of water in the composition result in a product having mechanical properties and physical characteristics. The preferred chemical coating compounds for the production of water-tight and water-repellent perlite particles are alkyl alkoxy silanes. Octyltriethoxy silane represents the most preferred alkyl alkoxy silane for coating the pearlite for use with the cement compositions of this invention.
[110] One of the preferred commercially available chemically coated perlite fillers is SIL-CELL 35-23 available from Silbrico Corporation. The SIL-CELL 35-23 perlite particles are chemically coated with the alkyl alkoxy silane compound. Another preferred chemically coated perlite filler is SIL-CELL 35-34 available from Silbrico Corporation. Perlite particles from SIL-CELL 35-34 are also useful in the cementitious compositions of the invention and are coated with silicone compound. DICAPERL 2010 and DICAPERL 2020 are other commercial coated perlite filler products produced by Grefco Minerals Inc. that are also preferred in this invention. DICAPERL 2010 pearlite, with alkyl alkoxy silane compound is particularly preferred in the cementitious compositions of the invention. DICAPERL 2020 pearlite, coated with silicone compound is also useful in the compositions of this invention.
[111] Another very useful property of the perlite fillers of this invention is that they exhibit pozzolanic properties due to their small particle size and silica-based chemical nature. Due to their pozzolanic behavior, the selected perlite fillers of the invention improve the chemical and water durability of cement compounds while developing improved interfaces and better bonding with cement binders and other ingredients present in the mixture.
[112] Yet, another extremely important benefit results from the small size of the perlite filler particles of this invention. The selected perlite fillers of the invention increase the overall amount of very fine particles (less than 75 microns) present in the composition. The presence of a high content of fine particles in the composition is extremely useful for the rapid processing of fiber-reinforced structural cement panels as it helps to improve the bond between the cement slurry and reinforcement fiber. The improved bond between the cement slurry and the reinforcement fiber leads to faster processing speeds of the panels and improved production recoveries. Additional Light Fillers / Microspheres
[113] Used as light fillers, microspheres help to decrease the average density of the product. When microspheres are hollow, they are sometimes referred to as microbalions.
[114] Microspheres are non-flammable by themselves or, if flammable, added in small enough quantities to not make the SCP panel flammable. Typical light fillers for inclusion in mixtures used to make the panels of the present invention are selected from the group consisting of ceramic microspheres, polymer microspheres, glass microspheres, and / or fly ash cenospheres.
[115] Ceramic microspheres can be manufactured from a variety of materials and using different manufacturing processes. While a variety of ceramic microspheres can be used as a filler component in the panels of the invention, the preferred ceramic microspheres of the invention are produced as a by-product of coal combustion and are a component of fly ash found in burnt coal utilities, for example, EXTENDOSPHERES-SG made by Kish Company Inc., Mentor, Ohio or FILLITE® brand ceramic microspheres made by Tolsa., Suwanee, Georgia USA. The chemistry of the preferred ceramic microspheres of the invention is predominantly silica (SiO2) in the range of about 50 to 75% by weight and alumina (Al2O3) in the range of about 15 to 40% by weight, with up to 35% by weight of other materials. The preferred ceramic microspheres of the invention are hollow spherical particles with diameters in the range of 10 to 500 microns (micrometers), the thickness of the shell, normally about 10% of the diameter of the sphere, and a particle density preferably of about 0 , 50 to 0.80 g / ml. The crushing strength of the preferred ceramic microspheres of the invention is greater than 1500 psi (10.3 MPa) and is preferably greater than 2500 psi (17.2 MPa).
[116] The preference for ceramic microspheres in the panels of the invention stems primarily from the fact that they are about three to ten times stronger than most synthetic glass microspheres. In addition, the preferred ceramic microspheres of the invention are thermally stable and provide greater dimensional stability for the panel of the invention. Ceramic microspheres find use in a variety of other applications, such as adhesives, sealants, seals, roof compounds, PVC floors, paints, industrial coatings and high temperature resistant plastic compounds. Although they are preferred, it should be understood that it is not essential that the microspheres are hollow and spherical, since it is the particle density and resistance to compression, which provide the panel of the invention with its low weight and important physical properties. Alternatively, irregular porous particles can be replaced, as long as the resulting panels meet the desired performance.
[117] Polymer microspheres, if present, are typically hollow spheres with a shell made of polymeric materials such as polyacrylonitrile, polymethacrylonitrile, polyvinyl chloride or polyvinylidine chloride or mixtures thereof. The shell may include a gas used to expand the polymer shell during manufacture. The outer surface of the polymer microspheres may have some kind of an inert coating such as calcium carbonate, titanium oxides, mica, silica and talc. The polymer microspheres have a particle density preferably of about 0.02 to 0.15 g / ml and have diameters in the range of 10 to 350 microns (micrometers). The presence of polymer microspheres can facilitate the simultaneous achievement of the low density of the panel and the improved cutability and fixation ability.
[118] Other light fillers, for example, glass microspheres, hollow aluminum silicate spheres or microspheres derived from fly ash, are also suitable for inclusion in mixtures in combination with or in place of the ceramic microspheres used to make the panels of the present invention.
[119] Glass microspheres are usually made of alkali-resistant glass materials and can be hollow. Typical glass microspheres are available at GYPTEK INC., Suite 135, 16 Midlake Blvd SE, Calgary, AB, T2X 2X7, CANADA. Other Chemical Additives and Ingredients
[120] Other additives, including water reducing agents such as superplasticizer, shrinkage control agents, slurry viscosity modifying agents (thickeners), coloring agents and internal curing agents, can be included as desired depending on the ability to processing and application of the cementitious composition of the invention.
[121] Chemical additives, such as water reducing agents (superplasticizers) can be included in the compositions of the invention and added in dry form or in the form of a solution. Superplasticizers help to reduce the water demand of the mixture. Examples of superplasticizers include polyphthalene sulfonates, polyacrylates, polycarboxylates, lignosulfonates, melamine sulfonates and the like.
[122] Depending on the type of superplasticizer used, the weight ratio of superplasticizer (based on dry powder) to reactive cement powder will normally be around 2% by weight or less, preferably around 0.1 to 1.0% in weight, more preferably from about 0.0 to 0.50% by weight, and even more preferably from about 0.0 to 0.20% by weight. So, for example, when the superplasticizer is present in the range of 0.1 to 1.0% by weight, for every 100 pounds of reactive cement powder in the mixture, there may be about 0.1 to 1 pounds of superplasticizer.
[123] Other chemical additives such as shrinkage control agents, coloring agents, viscosity modifying agents (thickeners) and internal curing agents can also be added to the compositions of the invention, if desired. Aggregates and Fillers
[124] While the disclosed reactive cement powder mixture defines the quick-setting component of the cementitious composition of the invention, this will be understood by those skilled in the art that other materials may be included in the composition, depending on its intended use and application.
[125] Depending on the amount of coated expanded pearlite used and the choice of the additional light filler selected, the weight ratio of the light filler to the reactive powder mixture can typically be 290%, preferably 4-50%, and most preferably , 8-40%.
[126] The moisture content of the aggregates adversely affects the laying time of cement mixtures. Thus, aggregates and fillers having low low water content are preferred in the present invention. Formulation of SCP Panels
[127] The components used to make the cut resistant panels of the invention include hydraulic cement, calcium sulfate alpha hemihydrate, an active pozzolan such as silica fume, lime, expanded hydrophobic perlite particles coated with or without ceramic microspheres or optional hollow glass, alkali-resistant glass fibers, superplasticizer (eg, sodium salt of polyphthalene sulfonate) and water. Normally, both hydraulic cement and calcium sulfate alpha hemihydrate are present. The long-term durability of the compound is compromised if calcium sulfate alpha hemihydrate is not present together with silica fume. The durability of water / moisture is compromised when Portland cement is not present. Small amounts of accelerators and / or retarders can be added to the composition to control the laying characteristics of the green (ie, uncured) material. Typical non-limiting additives include accelerators for hydraulic cement, such as calcium chloride, accelerators for calcium alpha sulfate hemihydrate as plaster, retarders such as DTPA (diethylene triamine pentacetic acid), tartaric acid or an alkaline salt of tartaric acid (for example, potassium tartrate), shrinkage-reducing agents such as glycols. The SCP panels of the invention do not contain added foaming agents and do not contain any entrained air.
[128] The panels of the invention will include a continuous phase, in which alkali-resistant glass fibers and the lightweight filler, for example, microspheres, are uniformly distributed. The continuous phase results from the curing of an aqueous mixture of reactive powders, (that is, a mixture of hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan and lime), preferably including the superplasticizer and / or other additives.
[129] TABLE 1 shows the weight proportions of the ingredients in the reactive powders (inorganic binder) of the present invention, for example, hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan and lime, based on the dry weight of 100 parts of the reactive powder.
[130] TABLE 1A lists the weight proportions of the ingredients in the cementitious compositions to be mixed with water to form slurries to form the panels of the present invention, for example, reactive powders, expanded coated perlite filling and glass fibers, based in the dry weight of 100 parts of the composition.
[131] TABLE 1B lists the weight ratios of the ingredients in the cimetitious compositions to be mixed with water to form slurries to form the panels of the present invention, for example, reactive powders, expanded coated pearlite and glass fibers, when microspheres of ceramics are also used as fillers, based on the dry weight of 100 parts of the composition.



[132] Lime is not required in all formulations of the invention, but it has been found that adding lime provides superior panels and, generally, 5 will be added in amounts greater than about 0.2% by weight. Thus, in most cases, the amount of lime in the reactive powders will be about 0.2 to 3.5% by weight.
[133] In accordance with the modalities of the present invention, non-flammable coated expanded perlite, which contains essentially no unburned carbon and few or no hollow ceramic microspheres containing unburned carbon, is generally sufficient to cause the panel SCP becomes flammable.
[134] In the embodiments of the present invention, slurry compositions of the present invention do not include foaming agents and the slurry does not require the use of any entrained air to reduce the density of the panel.
[135] The panel can be made as a single layer or as multiple layers. Typical water addition rates range from 35 to 70% by weight of reactive powders and particularly greater than 60% to 70% when the ratio of water-to-reactive powders is adjusted to reduce panel density and improve capacity of fixation and typical rates of addition for the superplasticizer will vary between 1 to 8% of the weight of the reactive powders. The preferred thickness of the outer layer (s) varies between 1/32 to 4/32 inches (0.8 to 3.2 mm) and the thickness of the outer layer, when only one is used, will be less than 3/8 of the total thickness of the panel.
[136] In multi-layered modalities with one or more core layers and opposite outer layers, both the core and the outer layer (s) of this embodiment of the present invention, independently, have a composition as described above , for example, in TABLES 1, 1A and 1B.
[137] If desired, at least one outer layer will have a higher percentage of glass fibers than the inner layer. If desired, at least one outer layer will improve the fixation capacity, resulting from an increase in the water-to-cement ratio in the outer layer (s) in relation to the inner layer (s) , and / or changing the amount of the filler, and / or adding an amount of polymer microspheres in the outer layer (s) relative to the inner layer (s). The amount of polymer microspheres, being small enough for the panel to remain non-flammable. Producing an Invention Panel
[138] Reactive powders powders, for example, mixture of hydraulic cement, calcium sulphate alpha hemihydrate, pozzolan and lime), and light filling, for example, coated expanded perlite particles, are mixed in the dry state in a suitable production mixer.
[139] Then, the water, a superplasticizer (for example, a polycarboxylated ether) and pozzolan (for example, active silica or metakaolin) are mixed in another mixer for 1 to 5 minutes. If desired, a retarder (for example, potassium tartrate) is added at this stage to control the settlement characteristics of the slurry. The dry ingredients are added to the mixer containing the wet ingredients and mixed for 2 to 10 minutes to form a smooth, homogeneous slurry.
[140] The slurry is then combined with glass fibers, in any of several ways, in order to obtain a uniform mixture of the slurry. The cement panels are then formed by pouring the slurry containing the fibers into an appropriate mold of the desired shape and size. If necessary, a vibration is provided to the mold to obtain good compaction of the material in the mold. The panel is given the necessary surface finish characteristics using a suitable leveling bar or trowel.
[141] One of several methods for making multilayer SCP panels is as follows. Reactive powders (for example, hydraulic cement mix, calcium sulfate alpha hemihydrate, pozzolan and lime) and the light filler comprising coated expanded perlite particles are mixed in the dry state in a suitable mixer. Then, the water, a superplasticizer (for example, a polycarboxylated ether) and pozzolan (for example, silica fume or metakaolin) are mixed in another mixer for 1 to 5 minutes. If desired, a retarder (for example, potassium tartrate) is added at this stage to control the settlement characteristics of the slurry. The dry ingredients and wet ingredients are mixed in a mixer for less than 10 minutes to form a smooth, homogeneous slurry.
[142] The slurry can be combined with the glass fibers in several ways, with the aim of obtaining a uniform mixture. The glass fibers will normally be in the form of wicks that are cut to short lengths. In a preferred embodiment, the slurry and the cut glass fibers are simultaneously sprayed into a panel mold. Preferably, spraying is done in a number of passes to produce thin layers, preferably up to about 0.25 inches (6.3 mm) thick, which are constructed on a uniform panel having no specific pattern and with a thickness 1/4 to 1 inch (6.3 to 25.4 mm). For example, in one application, a panel of 3 x 5 feet (0.91 x 1.52 m) was made with six passes of the spray in the length and width directions. As each layer is deposited, a roller can be used to ensure that the slurry and glass fibers reach intimate contact. The layers can be leveled with a leveling bar or other suitable means after the rolling step. Normally, compressed air will be used to atomize the slurry. As it leaves the spray nozzle, the slurry mixes with the glass fibers that have been cut from a wick through a cutting mechanism mounted on the spray gun. The uniform mixture of the slurry and glass fibers is deposited in the panel mold as described above.
[143] If desired, the outer surface layers of the panel may contain polymer spheres, or be constituted and otherwise, so that the fasteners used to secure the panel to the frame can be easily conducted, as long as the quantity of polymer spheres do not contain unburned carbon in quantities that would make the final panel flammable. The preferred thickness of such layers will be about 1/32 inch to 4/32 inch (0.8 to 3.2 mm). The same procedure described above by which the core of the panel is made can be used to apply the outer layers of the panel.
[144] Another method of producing the panels of the present invention is using the process steps disclosed in US Patent 7,445,738 incorporated herein by reference. US Patent 7,445,738 discloses after one of an initial deposition of loosely distributed, cut fibers or a layer of slurry on a mobile network, the fibers are deposited on the layer of slurry. A compact embedding device is the newly deposited fibers in the slurry, after which additional layers of slurry and then cut fibers are added, followed by further incorporation. The process is repeated for each layer of the plate, as desired. Upon completion, the board has a more evenly distributed fiber component, which results in relatively strong panels without the need for thick reinforcing fiber boards, as taught in prior art production practices for cement panels.
[145] More specifically, US Patent 7,445,738 discloses a multilayer process for the production of structural cement panels, including: (a.) The provision of a mobile network; layer of (b.) one of the deposit of a first layer of loose fibers and (c.) the deposit of a layer of the adjustable slurry on the mesh; (d.) depositing a second layer of loose fibers on the slurry; (e.) incorporating the second layer of fibers into the slurry; and (f.) the repetition of the slurry deposition from step (c.) to step (d.) until the desired number of layers of the configurable improved fiber slurry configurable in the panel is obtained.
[146] FIG. 3 is a diagrammatic elevational view of an apparatus that is suitable for carrying out the process of US Patent 7,445,738. Referring now to FIG. 3, a production line for the structural panel is shown diagrammatically and is generally designated 310. Production line 310 includes a support frame or training table 312 having a plurality of legs 313 or other supports. Included in the support frame 312 is a mobile loader 314, like an infinite conveyor belt similar to rubber, with a smooth surface, impermeable to water, however, porous surfaces are contemplated. As is well known in the art, the support frame 312 can be made of at least one table-like segment, which can include the designated legs 313. The support frame 312 also includes a main drive roller 316 at a distal end 318 of the frame and a tension roller 320 at a proximal end 322 of the frame. Also, at least one drive belt and / or tension device 324 is preferably provided for maintaining a desired tension and positioning of the conveyor 314 on the rollers 316, 320.
[147] Also, in the preferred mode, a net 326 of Kraft paper, release paper and / or other networks of support material intended to support the slurry before laying, as is well known in the art, can be supplied and placed on conveyor 314 to protect and / or keep it clean. However, it is also contemplated that the panels produced by the present line 310 are formed directly on the conveyor 314. In the latter situation, at least one belt washing unit 328 is provided. The conveyor 314 is moved along the support frame 312 by a combination of motors, pulleys, belts or chains that drive the main movement roller 316 as is known in the art. It is contemplated that the speed of the conveyor 314 may vary to suit the application.
[148] In the apparatus of FIG. 3, the production of the structural cement panel is initiated by one of the deposits of a layer of loose, cut fibers 330 or a layer of the slurry on the mesh 326. An advantage of the deposit of the fibers 330 before the first slurry deposit is that the fibers will be incorporated close to the outer surface of the resulting panel. A variety of depositing and fiber cutting devices are contemplated by the present line 310, however, the preferred system employs at least one rack 331 holding several spools 332 of fiberglass cable, each of which cable 334 or fiber it is fed to a cutting station or appliances, also referred to as a 336 cutter.
[149] The cutter 336 includes a rotating blade roller 338 from which it projects blades, extending radially 340, extending transversely across the width of the conveyor 314, and which is arranged in close relationship, contact, and rotation with an anvil roll 342. In the preferred embodiment, the blade roll 338 and the anvil roll 342 are arranged in a relatively close relationship such that the rotation of the laminated roll 338 also turns the anvil roll 342, however, the reverse also is contemplated. Also, the anvil roller 342 is preferably covered with a resilient support material against which the blades 340 cut the cables 334 in segments. The spacing of the blades 340 on the roll 338 determines the length of the cut fibers. As seen in FIG. 3, the cutter 336 is disposed above the conveyor 314 near the proximal end 322 to maximize the productive use of the length of the production line 310. As the fiber cables 334 are cut, the fibers 330 fall loosely on the conveyor network 326.
[150] Next, a slurry feeding station or slurry feeder 344 receives a slurry supply 346 from a remote mixing location 347 such as a funnel, box or the like. It is also contemplated that the process may begin with the initial deposition of slurry on the conveyor 314. The slurry is preferably composed of varying amounts of Portland cement, plaster, aggregate, water, accelerators, plasticizers, foaming agents, fillers and / or other ingredients, and described above and in the patents listed above which have been incorporated by reference for the production of SCP panels. The relative amounts of these ingredients, including the elimination of some of the above or the addition of others, may vary with use.
[151] While various configurations of the slurry feeders 344 are contemplated that uniformly deposit a thin layer of slurry 346 on the mobile conveyor 314, the preferred slurry feeder 344 includes a main measuring roller 348 disposed transversely to the direction of travel of the conveyor 314. A companion or a reserve of the roller 350 is arranged in a close parallel and rotational relationship to the measuring roller 348 to form a contact 352 between them. A pair of side walls 354, preferably made of non-stick material such as Teflon® brand material or the like, prevents the slurry 346 spilled in the contact space 352 from escaping out of the sides of the feeder 344.
[152] Feeder 344 deposits a relatively thin uniform layer of slurry 346 on mobile conveyor 314 or mesh of conveyor 326. The thicknesses of the appropriate layer vary from about 0.05 inch to 0.20 inch. However, with four preferred layers in the preferred structural panel produced by the present process and a suitable construction panel, being approximately 0.5 inch, an especially preferred layer thickness of the slurry is approximately 0.125 inch.
[153] Referring now to FIGs. 3 and 4, to achieve a slurry layer thickness as described above, several features are provided for the slurry feeder 344. First, to ensure a uniform arrangement of the slurry 346 throughout the entire network 326, the slurry is delivered to the feeder 344 through a hose 356 located in a motorized fluid dispenser, side driven, alternating cable 358 of the type well known in the art. The slurry flowing from the hose 356 is thus poured into the feeder 344 in a laterally alternating motion to fill a reservoir 359 defined by the rollers 348, 350 and the side walls 354. The rotation of the measuring roller 348 thus draws a layer of the slurry 346 from the reservoir.
[154] Next, a thickness monitoring or thickness control roller 360 is placed slightly above and / or slightly below a vertical centerline of the main measuring roller 348 to regulate the thickness of the slurry 346 drawn in the reservoir. feeder 357 on an external surface 362 of the main measurement 348. Also, the thickness control roller 360 allows the handling of fluid slurries with different viscosities and constantly changing. The main measuring roller 348 is guided in the direction of the "T" stroke according to the direction of movement of the conveyor 314 and the conveyor net 326 and the main measuring roller 348, the reserve roller 350 and the thickness monitoring roller 360 are all rotationally driven in the same direction, which minimizes the possibility of premature settlement of the slurry on the respective external movement surfaces. As the slurry 346, on the outer surface 362, moves towards the conveyor net 326, a stripping cross wire 364 located between the main measuring roller 348 and the conveyor net 326 ensures that the slurry 346 is completely deposited over the conveyor net and do not proceed back to contact space 352 and feeder reservoir 359. Stripping wire 364 also helps to keep main measuring roller 348 free of premature settling slurry and maintains a relatively curtain uniformity of the slurry.
[155] A second cutter station or apparatus 366, preferably identical to cutter 336, is arranged below the feeder 344 to deposit a second layer of fibers 368 on the slurry 346. In the preferred embodiment, the cutter apparatus 366 is fed by cables 334 from the same rack 331 that feeds the cutter 336. However, it is contemplated that separate racks 331 could be provided for each individual cutter, depending on the application.
[156] Referring now to FIGs. 3 and 5, then an embedding device, generally designated 370, is disposed in operational relation to the slurry 346 and the mobile conveyor 314 of the production line 310 to incorporate the fibers 368 into the slurry 346. While a variety of incorporation is contemplated, including, but not limited to vibrators, sheepskin rollers and the like, in the preferred embodiment, the incorporation device 370 includes at least one pair of axes generally parallel 372 mounted transversely to the direction of the "T" stroke of the conveyor network 326 in table 312. Each axis 372 is provided with a plurality of relatively large diameter discs 374 which are axially separated from each other on the axis by small diameter discs 376.
[157] During the production of the SCP panel, shafts 372 and discs 374, 376 rotate together over the longitudinal spindle of the shaft. As is well known in the art, both one and two axles 372 can be motorized, and if only one is motorized, the other can be driven by belts, chains, gear drives or other known energy transmission technologies to maintain a direction corresponding speed for the driving roller. The respective disks 374, 376 of the adjacent axes, preferably parallel 372 interact with each other to create a "kneading" or "massage" action on the slurry, which incorporates the fibers 368 previously deposited therein. In addition, the close, interaction and rotation ratio of the disks 372, 374 prevents the build-up of fluid paste 346 on the disks and, in effect, creates a "self-cleaning" action, which significantly reduces line downtime of production due to the premature settlement of agglomerates of slurry.
[158] The interaction relationship between discs 374, 376 on axes 372 includes a closely adjacent arrangement of opposite peripheries of small diameter spacer discs 376 and main discs of relatively large diameter 374, which also facilitates self-cleaning action . As the disks, 374, 376 rotate in relation to each other in close proximity (but preferably in the same direction), it is difficult for particles of the slurry to be caught in the apparatus and prematurely set. By providing two sets of discs 374, which are offset laterally in relation to each other, the slurry 346 is subjected to various disturbing actions, creating a "kneading" action that further incorporates the fibers 368 into the slurry 346.
[159] Once the fibers 368 have been incorporated, or in other words, as the mobile web carrier 326 passes the inlay device 370, a first layer 377 of the SCP panel is complete. In the preferred embodiment, the height or thickness of the first layer 377 is the approximate range of 0.05-0.20 inches (1.3 to 5.1 mm). This variation was found to provide the desired strength and stiffness when combined with layer types on an SCP panel. However, other thicknesses are contemplated depending on the application.
[160] To build a structural cement panel of a desired thickness, additional layers are required. For this purpose, a second slurry feeder 378, which is substantially identical to the feeder 344, is provided in operational relation to the mobile conveyor 314 and is arranged to deposit an additional layer 380 of the slurry 346 on the existing layer 377.
[161] Next, an additional cutter 382, substantially identical to cutters 336 and 366, is provided in operational relation to frame 312 to deposit a third layer of fibers 384 supplied from a rack (not shown) constructed and arranged in relation to the structure 312 similarly to rack 331. The fibers 384 are deposited on the slurry layer 380 and are incorporated using a second inlay device 386. Similar in construction and arrangement to the inlay device 370, the second inlay device 386 is mounted a little higher above the mobile carrier network 314 so that the first layer 377 is not altered. In this way, the second layer 380 of slip and embedded fibers is created.
[162] Now referring to FIG. 3, with each successive layer of slurry and settable fibers, a slurry feeding station 378, 402 is provided on production line 310 followed by a fiber cutter 382, 404 and an inlay device 386, 406. preferably, a total of four layers (see, for example, panel 21 in Fig. 2) are provided to form the SCP panel. After the arrangement of the four layers of settable slurry permeated by fibers as described above, a forming device 394 is preferably provided to structure 312 to form an upper surface 396 of the panel. Such forming devices 394 are known in the art of producing slurry / settable plate, and are typically spring or vibration plates, which conform to the height and shape of the multilayered panel to suit the desired dimensional characteristics.
[163] The panel made has several layers (see, for example, layers 22, 24, 26, 28 of panel 21 of FIG. 2) which, after gripping, form an integral mass reinforced with fibers. As long as the presence and positioning of the fibers in each layer are controlled by and maintained within certain desired parameters as disclosed and described below, it will be virtually impossible to laminate the panel.
[164] At this point, the pickling of the slurry layers has started, and the respective panels are separated from each other by a cutting device 398, which is a waterjet cutter in the preferred mode. Other cutting devices, including moving blades, are considered suitable for this operation, as long as they can create appropriately sharp edges in the current composition of the panel. The cutting device 398 is arranged in relation to the line 310 and the structure 312 so that the panels are produced in a desired length, which may be different from the representation shown in FIG. 3. Since the speed of the conveyor network 314 is relatively low, the cutting device 398 can be mounted to cut perpendicular to the direction of travel of the network 314. With higher production speeds, it is known that such cutting devices are mounted on production line 310 at an angle to the direction of travel of the network. After cutting, the separate panels 321 are stacked for handling, packaging, storage and / or future shipping, as is known in the art.
[165] The number of layers of fiber and slurry, the volume fraction of the fibers in the panel and the thickness of each layer of slurry and the diameter of the fiber yarn influence the fiber encrusting efficiency. The following parameters were identified: VT = Total volume of compound VS = Total volume of slurry from panel VF = Total volume of fiber from panel VF, L = Volume / total layer of fiber VT, L = Total volume / layer of compound VS , L = Total volume / layer of the slurry NL = Total number of layers of the slurry; Total number of fiber layers VF = Fraction of the total fiber volume of the panel DF = Equivalent diameter of the individual fiber yarn LF = Length of the individual fiber yarn t = Panel thickness TL = Total thickness of the individual layer, including the slurry and TS fibers, L = Thickness of the individual layer of slurry ng, nfi.i, ng.i = Total number of fibers in a fiber layer sp, L ^ sp, L ^ sp 2, L = Total projected surface area of fibers contained in a fiber layer SFP, I, SFP1, I, SPF2.1 = Fraction of fiber surface area designed for a fiber layer.
[166] Assumes a panel made up of an equal number of layers of fiber and slurry. The fraction of the projected fiber surface area, S FP, I of a fiber network layer being deposited on a separate layer of slurry is given by the following mathematical relationship:
where, VF is the volume fraction of the total fiber of the panel, T is the total thickness of the panel, DF is the diameter of the fiber wire, NI is the total number of fiber layers and TS, I is the thickness of the distinct layer of the slurry being used.
[167] Likewise, in order to achieve good fiber fouling efficiency, the objective function becomes to keep the fiber surface area fraction below a certain critical value. Ranging from one or more variables that appear in the equations, the projected fiber surface area fraction can be adapted to achieve good fiber encrustation efficiency.
[168] Different variables that affect the magnitude of the projected fiber surface area fraction are identified and approaches have been suggested to adapt the magnitude of the "projected fiber surface area fraction" to achieve good fiber encrustation efficiency. These approaches involve varying one or more of the following variables to keep the projected fiber surface area fraction below a critical threshold value: number of different layers of fiber and slurry, thickness of the different layers of the slurry and the fiber wire diameter.
[169] The preferred magnitudes of the projected fiber surface area fraction, S FP, L are as follows: Preferred projected fiber surface area fraction '', L <0.65 Surface area fraction of preferred projected fiber, Sf, L <0.45
[170] For a fraction of fiber volume of the projected panel, Vf, obtaining the preferred magnitudes of the projected fiber surface area mentioned above can be made possible by adapting one or more of the following variables - total number of layers of different fiber, different thickness of the slurry layers and diameter of the fiber yarn. In particular, the desirable variations for these variables that lead to the preferred magnitudes of the fraction of the projected fiber surface area are as follows:
[171] Thickness of Different Layers of Slurry in SCP Multi-Layer Panels, t, L Preferred thickness of different layers of slurry, ts, L <0.30 inches (7.62 mm) Preferred thickness of different layers of slurry, ts, L <0.20 inches (5.08 mm) Preferred thickness of separate layers of slurry, ts, L <0.08 inches (2.32 mm)
[172] Number of distinct fiber layers in SCP multi-layer panels, N, Preferred number of distinct fiber layers, N,> 4 Preferred number of distinct fiber layers, N,> 6
[173] Fiber Yarn Diameter, df 5 Preferred Fiber Yarn Diameter, df> 30 tex Preferred Fiber Yarn Diameter, df> 70 tex PROPERTIES
[174] The metal frame system of the SCP panel of the present invention preferably has one or more of the properties 10 listed in TABLES 2A-2F. The properties are for panels with thicknesses greater than 1/2 inch (12.7 mm) for applications shown in the TABLES.













[175] The panels of the present invention typically have a nominal structural supporting strength (structural strength) of at least 200 pounds per linear foot (298 kg per linear meter), preferably 720 pounds per linear foot (1072 kg per linear foot) meter). A system that has 3 / 8-3 / 4 inch thick SCP panels. (9-19 mm), for example 1/2 inch (12.5 mm), propped laterally mechanically and / or adhesive by metal frames when tested according to ASTM E-72 usually has a nominal structural capacity of the wall (also known as nominal structural strength of support) from 200 to 1200, or 400 to 1200 or 800 to 1200 pounds per linear foot. The structural panels of the present invention typically have a nominal structural supporting strength (structural strength) of 720 lbs / ft (1072 kg / m) before a failure occurs. For example, when used for walls, the nominal structural support strength of a 0.5 inch (12.7 mm) thick panel measured by the ASTM E72 test using pins, metal cleats, screw spacing and cleat spacing it is typically at least 720 lbs. per linear foot (1072 kg per linear meter).
[176] The rated structural support strength is measured to determine the load that the panel can withstand within the permitted deflection without failure. The structural classification is generally based on tests of three identical sets of 8 X 8 feet (2.44 x 2.44 m), that is, the panels attached to the frame. An edge is attached while a lateral force is applied to a free end of the assembly until the load is no longer supported and the assembly fails. The structural strength measured will vary, depending on the thickness of the panel and the size and spacing of the nails used in the set. For example, a typical set, for example, a plywood of nominal 1/2 inch (12.7 mm) thickness, would be expected to be fastened with 8d nails (see nail description below) for 2 x nominal wooden pins 4 inches (50.8 x 101.6 mm) spaced 16 inches (406.4 mm) apart (in the centers), nails being spaced 6 inches (152.4 mm) apart at the perimeter and 12 inches ( 304.8 mm) distance within the perimeter, show a structural resistance of 720 lbs / foot (1072 kg / m) before the failure occurs (Note the measured resistance will vary as the nail size and spacing are changed, according to with the ASTM E72 test). This final strength will be reduced by a safety factor, for example, a factor of three, to define the structural design strength for the panel. EXAMPLES
[177] The following examples illustrate the performance and benefits of using finely coated expanded pearlite as a partial or total replacement for hollow ceramic microspheres in a typical formulation for SCP panels. All mixtures comprise, on a dry basis, a reactive powder cement binder consisting of alpha calcium sulphate hemihydrate, Portland cement, silica fume and lime provided in 65, 22, 12 and 1%, respectively, by weight, of total cement binder. In previous SCP formulations, containing only ceramic microspheres, the filling ratio of hollow microsphere to binder is normally 0.44: 1.00 weight.
[178] In the formulation of the present invention with finely coated expanded perlite and optional ceramic microspheres, the ratio of perlite to ceramic microsphere to binder is 0.053: 0.20: 1.00 by weight. In the preferred formulation of the invention, which uses only the finely coated expanded perlite filler, the ratio of perlite to binder is within the range of about 0.07 to 0.15: 1.00 by weight. The examples are provided to illustrate the performance and benefits incurred by using finely coated expanded pearlite as a partial or total replacement for hollow ceramic microspheres in a previous SCP formulation. Perlite are SIL-CELL 35-23 perlite particles from Silbrico Corporation of Hodgkins, IL 60525, which are coated with the alkyl alkoxy silane compound. All of the mixtures described here and used in the following Examples comprise a reactive powder cement binder on a dry basis, calcium sulfate alpha hemihydrate, Portland cement, silica fume and lime provided at 65, 22, 12 and 1%, respectively by weight of total cement binder.
[179] In contrast to previous SCP formulations in which water was used in a weight ratio of 0.57: 1.00 to the cement binder, the water weight ratio to the reactive cement powder binder in the present invention is 0.47: 1.00 for the ceramic pearl and microsphere formulation and 0.44: 1.00 for the preferred formulation, where finely coated expanded pearlite is used and there is no ceramic microsphere filler. Chemical additives such as superplasticizer (polycarboxylate ether) to control the demand for water and tartaric acid for configuration control varied according to the objectives of a specific experiment.
[180] The examples illustrate how perlite formulations behave in a number of performance requirements and how they can be made similar to, or better than, the original formulation using ceramic microspheres for certain properties. The relevant experimental procedures for each example are briefly described with the example. Whenever the term "perlite" is used, it refers to an expanded perlite in a particle size range of 1 to 150 μm and an average particle size in the range of about 20 to 60 μm, for example 40 μm, which is treated with a silane coating. The acronym "MS" is used to describe ceramic microspheres. Example 1
[181] This example shows the slurry properties of mixtures containing different amounts of perlite as a filler compared to the original mixture using ceramic microspheres (MS). The typical properties of the relevant slurry are the slump, the density of the slurry, the setting time and the compression effort at different ages (7,14 and 28 days). Mix all ingredients that have been preconditioned in sealed plastic bags for laboratory conditions at 75-80 ° F (23.9 to 26.7 ° C) for at least 24 hours before mixing, followed by mixing using a Hobart at medium speed in order to achieve uniform dispersion. Dry powders, which include fillers and cement binder, were provided in the amounts indicated above under the heading Examples. The superplasticizer was added in a dosage of 0.41% by weight of cement binder for MS mixtures, 0.47% for partial mixtures of perlite and 0.530.56% for total mixtures of perlite. Tartaric acid was added in varying dosages depending on the specific experiment.
[182] Slump was measured by filling a brass cylinder that is 4 "(10.2 cm) high x 2" (5.1 cm) in diameter with the mixture in question, leveling the upper end of the cylinder to remove excess material, raising the cylinder vertically in 5 seconds to allow the slurry to spread and measuring the diameter of the formed slurry pellet. The density of the slurry was measured by filling a plastic cylinder that is 6 "(15.2 cm) high x 3" (7.6 cm) in diameter with the mixture, leveling the upper end of the cylinder in order to removing excess material and weighing the amount of material in the cylinder. Knowing the volume of the cylinder, the density of the slurry was then calculated. The final and initial setting times were determined using Gillmore needles according to ASTM C 266, while the compression effort was determined in 2 "(5.1 cm) cubes according to ASTM C 109.
[183] The abatement of the mixtures described in this example for the different molding dates is shown in FIG. 6. In particular, FIG. 6 shows the Abatement of formulations prepared with ceramic microspheres, partial perlite and total perlite (MS = microsphere, Partial = partial perlite, Total = complete perlite). The dosage of tartaric acid as percent by weight of cement binders is shown by values above the bars.
[184] The first two bars compare the abatement of mixtures with ceramic microspheres (MS) and partial pearlite (Partial).
[185] The rest of the bars compare the slump of the mixtures with the ceramic microspheres (MS) and the total perlite (Total) for each of the different mold dates. In general, it is seen that perlite formulations can be made at the same degree of initial fluidity and machinability as formulations with MS without the need for excessive adjustments to the amount of chemical additives (changes in fluidity with time will be addressed in the Example two). Through the combination of proportions of cement binder and additives described in this specification, the machinable mixture can be made.
[186] The density of the slurries covered in Fig. 6 is shown in Fig. 7. In particular, FIG. 7 shows the density of the slurry of formulations prepared with ceramic microspheres, partial perlite and total perlite (MS = microsphere, Partial = partial perlite, Total = complete perlite). The dosage of tartaric acid as percent by weight of cement binders is shown by values above the bars. It is seen that with the combination of the proportions and additives of the cement binder described in this specification, mixtures on the same density scale as the original mixture with the MS filler can be provided. In the commercial production of SCP panels, slurries with density in the range of 78-83 pcf (1,251.33 g / cc) are normally obtained.
[187] Grip times are generally evaluated in terms of an initial handle and a defined end using Gillmore needles according to ASTM C 266. For comparison purposes, only the initial handle is illustrated here as shown in Fig. 8 for mixtures covered in FIGURES 6 and 7. In particular, FIG. 8 shows the initial take of formulations prepared with ceramic microspheres, partial perlite and total perlite (MS = microsphere, Partial = partial perlite, Total = complete perlite). The dosage of tartaric acid as percent by weight of cement binders is shown by values above the bars.
[188] In general, the catch of mixtures containing perlite (especially total perlite) to be defined faster than mixtures of DM, when the dosage of tartaric acid was fixed by percentage weight of cement binder. The actual setting behavior, however, can be modified by adjusting this dosage of tartaric acid.
[189] Compressive strength of cubes is usually evaluated at various ages after initial casting (7, 14 and 28 days). For comparison purposes, only the 28-day compressive strength is illustrated here as shown in FIG. 8 for the mixtures covered in FIGURES 6-8. In particular, FIG. 9 shows the compressive strength of 28 days of formulations prepared with ceramic microspheres, partial perlite and total perlite (DM = microsphere, Partial = partial perlite, Total = complete perlite). The days in Figures 6-9 reflect the next dosage of tartaric acid as a percentage by weight of cement binders shown by values above the bars.
[190] For the partial perlite mixture, its resistance was in the same range as the MS mixture. For the partial perlite mixture, there was more vulnerability in the test results and, in several cases, it was higher than the corresponding control mixture. The compressive strength of the target slurry for SCP production is 2500 psi (17.2 MPa) in 28 days, which is exceeded by all mixtures evaluated here.
[191] In general, as shown in this example, the commonly measured properties of the slurry (slump, density, setting time and compression stress) for formulations containing the coated expanded pearlite filler of the invention, as a partial or total substitute for filling of conventional MS used can be adjusted to provide the same properties as the formulation conventionally used to make SCP panels. Minor adjustments to the dosage of superplasticizer and tartaric acid can be made to adapt the particular blend of pearlite to the actual production conditions. Example 2 - Slurry Loss Loss Behavior.
[192] A critical material property in the manufacture of SCP panels is the slump loss of slurry. Normally, the relatively high flowability of the slurry is desired in the early stages of the forming line where the slurry is mixed and formed, while a hard and very low flow material (preferably after setting) is desired in the last stages of the forming line. when the SCP panel is cut and transferred to cars. Therefore, mixtures with higher rates of loss of slaughter are more desirable.
[193] In this example, five mixtures were evaluated (2 with DM and 3 with total perlite) with different tartaric acid content. The proportion of cement binders for these mixtures was as described above and the superplasticizer was added to a content of 0.45% and 0.56% of cement binder by weight for the mixtures of DM and total perlite, respectively. Tartaric acid was added in dosages of 0.008 and 0.02% of cements by weight for the two mixtures of DM and in dosages of 0.01, 0.02 and 0.03% of cements by weight for mixtures of total perlite . For these five mixtures, the drop loss and initial catch were measured, and this behavior is shown in FIGS. 10a, b. In particular, FIGS. 10 (a) and 10 (b) show the loss-depletion behavior of mixtures of DM and complete perlite at different dosages of tartaric acid (abscissa data points represent the time when the initial take up of slurries occurred).
[194] Fig. 10a shows the slump versus the time behavior for each mixture, while FIG. 10b shows the rebate as a percentage of its initial value versus the time for each mixture. The specific data points on the abscissa (that is, at abate = 0) represent the time when the initial catch occurred. It is observed here that the catching of total perlite mixtures tended to occur a little earlier than the mixtures of MS when similar doses of tartaric acid were used. What is probably more significant is that mixtures of total perlite lost slaughter at a faster rate than the DM mix, and this loss of slaughter was almost immune to the amount of tartaric acid added. This higher slump loss rate is beneficial for manufacturing as described earlier as it allows for greater initial fluidity for fiber formation and encrustation, followed by the rapid hardening of the material for back-end operations. In addition, the high rate of loss of slaughter also implies that faster manufacturing speeds may be feasible. Example 3 - Flexural Performance of Fiber Reinforced Panels
[195] In this example, fiberglass reinforced cement panels were made using partial and total perlite formulations to assess the panel's flexural performance. The dry powder consisting of cement binder and filler (CM, partial perlite or total perlite) was separated into batches according to the proportions described in "Description". The AR chopped glass fiber was added to the mixture in such a way that the resulting fiber content in the panel was 2.5% by volume. Panels were made using XY equipment that delivers the slurry through a spray nozzle while providing the chopped glass fiber through a cutter attached to the slurry spray nozzle. The slurry flow and fiber shear rate were calibrated in such a way that the resulting fiber content in the product was 2.5% by volume. Panels of three feet by six feet (3 'x 6') (0.91 mx 1.8 m) were produced and samples of 6 "x 12" (15.2 cm x 30.5 cm) were cut by these saws panels. Following the cutting of the panels, the samples were cured with moisture until their tests with 14 or 28 days, according to ASTM C 1185. Each test consisted of 6 replicated samples. A total of two rounds of panels were made for replication.
[196] The flexural performance of structural panels is characterized by two main parameters: strength and rigidity. Due to the varying thickness of the panels produced, the different mixtures are compared here based on the Rupture Module (MOR) and Apparent Elasticity Module (AMOE) as these parameters are normalized in relation to the sample size. FIG. 11 (a), (b) presents the MOR and AMOE in 14 days for panels made in the two rounds. In particular, FIGS. 11 (a) and 11 (b) show the flexural performance of panels made with ceramic microspheres, partial perlite and total perlite (MS = microsphere, Partial = partial perlite, Total = total perlite) in 14 days.
[197] FIGS. 12 (a), (b) present the MOR and AMOE in 28 days for panels made in the two rounds. In particular, FIGS. 12 (a) and 12 (b) show the flexural performance of panels made with ceramic microspheres, partial perlite and total perlite (MS = microsphere, Partial = partial perlite, Total = total perlite) in 28 days. The 95% confidence interval for the data set is also shown in the bars. It was found that with perlite as a partial or total substitute for DM in the mixture, similar or greater flexural strength (MOR) can be achieved in the panels. These results indicate that the cement and fiber matrices were still able to develop suitable interface properties and compound behavior in the presence of perlite as a filler. Regarding flexion stiffness (AMOE), a slightly higher variation was observed in the test data. In general, perlite mixtures exhibited AMOE in the same range as those in MS mixtures, which indicated similar matrix stiffness for all tested mixtures. These results demonstrate that formulations containing perlite as a filler or as a partial or total replacement of the DM, can be provided to produce panels that have similar flexural performance. For reference, the minimum specification requirement for floor covering applications is 1288 psi (8.88 MPa) for MOR, which corresponds to the minimum moment capacity of 1450 lbf-in / ft (537 N-m / m) for a % inch (19 mm) choice panel, as set out in the Acceptance Criteria ICC-ES AC-318 and ASTM C 1705. The minimum specification requirement for AMOE is 529 ksi, which corresponds to a flexural stiffness 223,000 lbf-in2 / ft (2,100 N-m2 / m) for a% inch (19 mm) choice panel, determined in the ICC-ES Acceptance Criteria AC-318 and ASTM C 1705. All samples tested exceeded those specifications. Example 4 - Durability to Moisture
[198] From the panels described in Example 3, the samples were also obtained for moisture durability tests. This test involves immersing 6 "x 12" (15.2 cm x 30.5 cm) samples in water at room temperature for 48 hours after curing for 28 days and then flexing according to ASTM C 1185. The ratio of dry to wet flexural strength is then calculated according to the specifications for moisture durability and floor covering panel require a minimum of 70% strength retention. FIG. 13 shows the wet MOR for the various mixtures in the two test runs. In particular, FIG. 13 shows the MOR after 48 hours immersion of panels made with ceramic microspheres, partial perlite and total perlite (DM = microsphere, Partial = partial perlite, Total = total perlite).
[199] It is observed here that the panels with perlite consistently showed a higher MOR than the control panels (almost 10-20% difference). The retention of wet strength for these panels, calculated as (Average Wet MOR) / (Average Dry MOR in 28 days) x 100%, for the 6 panels evaluated is shown in TABLE 3. This table shows that with perlite coating in the formulation, the panels had a higher retention of wet strength, which implies greater hydrophobicity in perlite formulations. Greater retention of strength is particularly advantageous for panels exposed to wet conditions, such as during transportation and installation on the construction site.
[200] FIG. 14 shows the AMOE after 48 hours immersion of panels made with ceramic microspheres, partial perlite and total perlite (MS = microsphere, Partial = partial perlite, Total = total perlite). Although not part of a product specification, the stiffness retention based on the wet AMOE values of FIG. 14 was also calculated and shown in TABLE 4. It is again observed that mixtures of perlite had higher stiffness retention values compared to mixtures of DM.

[201] As shown in Table 3, the wet flexural strength retention values for the formulations of the invention are all greater than 70%, which is the minimum specification established in the Acceptance Criteria AC-318 of the ICC-ES and in ASTM C 1705 standard.
Example 5 - Freeze and Thaw Durability
[202] The samples were also obtained from panels made during the first round of production for freeze-thaw testing according to ASTM C 1185. This test involves first soaking the samples (6 "x 12") (15.2 x 30.5 cm) in water at room temperature for 48 hours, sealing them and then subjecting them to 50 cycles of freezing and thawing following the temperature-time regime specified in the test method, then immersing them in water again for 48 hours and testing flexion. The resistance after the completion of 50 freeze-thaw cycles is compared to the resistance of the control samples that were exposed only to 48 hours of immersion in water at room temperature (Example 4). The strength and stiffness retention values were calculated and shown in TABLE 5-1. Retention values were generally excellent at approximately 100% or above, indicating that there was no loss of performance. For strength retention, the typical commercial specification value is 75%, which has been exceeded by all mixtures.
[203] As shown in Table 5-1, the wet flexural strength retention values for the formulations of the invention are all greater than 75%, which is above the minimum specification established in the ICC- Acceptance Criteria AC-318 ES and ASTM C 1705.

Example 6 - Long-Term Durability
[204] Samples of panels from the first round of production were taken for the long-term durability test according to ASTM C 1185. This test involves soaking the samples (6 "x 12") (15.2 x 30.5 cm) in water at 140 ° F (60 ° C) for 56 days, followed by the flexion test. The resistance after the completion of immersion in hot water is compared to the resistance of the control samples that were exposed to only 48 hours of immersion in water at room temperature (Example 4). For the panels in question, the strength and stiffness retention values were calculated and shown in TABLE 6-1. The retention values were generally excellent with values greater than 90%. For strength retention, the typical commercial specification value is 75%, which has been exceeded by all mixtures, including perlite formulations.

[205] As shown in Table 6-1, the formulations of the invention at flexural strength retention values greater than 75%, which is the minimum specification established in the Acceptance Criteria AC-318 of the ICC-ES and in the ASTM C standard 1705. Example 7- Lateral Fixation Resistance
[206] Samples of 4 "x 12" (10.2 X 30.5 cm) were taken from panels made during the second round of production, for testing the lateral fixation resistance, which measures the resistance of one edge of the panel the cut due to the traction of the lateral fastener. This property is a key property for the cutting diaphragm behavior of floor panels. The specific procedure adopted here for this evaluation was to drill a% "(0.64 cm) hole in the sample at a distance of />" (1.3 cm) from the 4 "(10.2 cm) edge of the sample . A steel plate with a% "(0.64 cm) shank was then mounted to the sample with the shank inserted into the sample hole. The steel plate and sample set was then disassembled to force the sample to fail over the 1/2 "(1.3 cm) cover. The maximum load recorded during the fracture process was recorded as the strength of the lateral fixation element This test was performed on samples in dry and wet conditions (48 hour immersion) The results of this test are shown in Figure 15 for dry samples and in Figure 16 for wet samples Each test consisted of 10 Figure 15 shows the Resistance of the Dry Lateral Fixing Element for samples of panels made with ceramic microspheres, partial perlite and total perlite, Fig. 16 shows the Resistance of the Wet Lateral Fixation Element of panel samples made with ceramic microspheres, partial perlite and total perlite.
[207] The total variation of test data is seen in FIGS. 15 and 16 and this is due to the variation in the sample thickness, which directly affected the measured load. Note also the average sample thickness in the graphs. However, at the 95% confidence interval, it is observed that the population groups were essentially similar. On average, the total perlite mixture exhibited the greatest resistance of the lateral fixation element, despite being a little thinner compared to the MS mixtures. The minimum commercial specification requirements for this property are 210 lbs (95.3 kg) (dry) and 160 lbs (72.6 kg) (wet), in accordance with the minimum specification set out in the ICC Acceptance Criteria AC-318 -ES and ASTM C 1705.
[208] The results for the perlite mixtures are reproduced below in TABLE 7-1, together with the data corresponding to the light cement-based panels of the prior art, which have been elaborated from the composition established in TABLE 7-2. Due to the difference in thickness between the samples, the LFR values were normalized to a thickness of 0.75 "(19 mm), as shown in the table. SCP perlite formulations outperformed the lightweight cement-based panel formulation four times A fundamental reason for this difference was the type and distribution of fiberglass in the products In the case of SCP, the reinforcement of laminated and randomly dispersed fibers made it more effective in stopping the growth of cracks in all directions throughout the thickness of the panel, compared to the surface reinforcement oriented in light cement panels of the prior art. Differences in the core structure between the two products also play a role in this difference, with the SCP formulation being a denser product The proportion of water and cement material in the light cement-based panel of the previous technique of 5 TABLE 7-1 and 7-2 is 0.62.
TABLE 7-2
100 parts of Portland Cement by weight, 30 parts of fly ash by weight and 3 parts of plaster by weight. 10 Perlite Sil-Cel 35-23: Coated silane with an average particle size of about 40 microns. Net totals of an aqueous solution of aluminum sulphate - 0.10% by weight; Triethanolamine - 0.40 by weight. %; Naphthalene sulphate with plasticizer base - 0.30% by weight and Sodium Citrate - 0.20% by weight, in which all weight percentages are based on the weight of the Portland cement-based binder. The air entrained in the compound is provided by the addition of sodium alpha olefin sulfonate surfactant at a dosage rate of 0.0069% by weight based on the total weight of Example 8 - Bearing Capacity As described in more detail in Example 14, below, the fiber-reinforced panels were made using the formulations of MS, partial perlite and total perlite for a small-scale fire test. From these same panels, samples of 6 "x 6" (15.2 x 15.2 cm) were extracted to assess the carrying capacity. In this test, a square of 2 "x 2" (5.1 x 5.1 cm), steel block with flat ends, was positioned in the center of the sample 6 "x 6" (15.2 x 15.2 cm) . Using a universal test board, the steel block and sample were preloaded to around 5 pounds (2.27 kg). The steel block was then pressed into the sample at a rate of 0.012 in. / min (0.3 mm / minute) while deflection was measured. The test was completed when the sample deflection was a 0.10 "(25.4 cm) compression. Upon completion of the test, the sample was removed and the thickness of the compacted and unzipped was recorded to determine the" permanent grip " The carrying capacity (in pounds) for the various samples tested is shown in Fig. 17 at different deflection levels Fig. 17 shows the carrying capacity of samples of panels made with ceramic microspheres, partial perlite and total perlite Also shown in Figure 17, the results of a commercial production panel from the manufacturing plant (using MS) serve as a comparison Each bar corresponds to the average of 5 samples. form for the mixture of DM, especially in the case of partial perlite. For total perlite, there was more variation in the test result, as shown by comparatively higher values in lower deflections and comparatively lower values in lower deflections iores. The measured permanent grip of these samples is shown in FIG. 18 where it can be seen that all panel tests (except for the production panel) were shown to have a permanent handle in the same range. Thus, from these test results, it is evident that mixtures of perlite (partial or total) offered similar levels of carrying capacity for the MS mixture. Example - Water Absorption Panels made during a second round of production were tested for the wetting behavior of the mixture. Water absorption was assessed using 4 "x 4" (10.2 x 10.2 cm) samples cut with a panel saw. These samples (6 per set) were soaked in water at room temperature and their weight monitored during an immersion period of 21 days. The weight percentage gain from the initial weight was recorded as water absorption. For the three mixtures evaluated, this property is shown in FIG. 19, which shows the water absorption by samples of panels made with ceramic microspheres, partial perlite and total perlite. FIG. 19 shows that the perlite mixtures absorbed considerably less water than the microsphere mix (MS mix) over the duration of the test. The first hour absorption, which is indicative of the tendency to draw water in contact, was 5.0% (DM), 3.1% (Partial) and 2.5% (Total). The 48-hour absorption values were 8.0% (DM), 5.6% (Partial) and 4.7% (Total). Thus, in the first 2 days after contact with water, the total perlite absorbed 50-60% of the water absorbed by a mixture of DM. The typical specification value for absorption of 48 hours is 15% maximum), in accordance with the minimum specification established in the Acceptance Criteria AC-318 of the ICC-ES and in the standard ASTM C 1705. Example 10 - Linear Expansion Panel samples with 6 "x 12" (15.2 x 30.5 cm) were prepared from panels made during production for linear expansion testing using a test procedure modified by ASTM C 1185. Each sample was assembled with brass studs, placed in pairs 10 "apart on each of the upper and lower surfaces of the sample to serve as reference points for measurements of change in length. The measured average length change of the upper and lower surfaces of the sample was recorded as the change in length than a given sample.The samples were first balanced in an oven at 130 ° F (54 ° C) until they reached a constant length (next shrinkage) and then submerged in water at room temperature. the environment until its length stabilizes again (expansion of the next). The linear expansion was then calculated as the difference in length between the expanded and shrunk states, expressed as a percentage of the initial useful length of the sample (10 ") (25.4 cm). In this example, each assay consisted of 5 -6 replicated samples The linear expansion for the evaluated mixtures is shown in Figure 20. In particular, Figure 20 shows the linear expansion of panel samples made with ceramic microspheres, partial perlite and total perlite. , in general, that perlite specimens tended to expand a little more compared to MS specimens. Typical specifications require linear expansion of specimens at 0.10% maximum, according to the specification set out in Acceptance Criteria I AC -318 of the ICC-ES and in the ASTM C 1705 standard. And this test, the linear expansion is measured as the percentage difference in the length of a sample going from equilibrium conditions at 73 ± 4 ° F and 30 ± 2% relative humidity. equilibrium conditions at 73 ± 6 ° F and relative humidity of 90 ± 5%. Since the conditions under which the samples were subjected to this study were considerably stricter than those described in ASTM C 1185, it would be expected that the mixtures investigated in this study would exhibit lower expansion values than those shown in FIG. 20 if they had been tested for ASTM C 1185 conditions. Example 11 - Non-combustibility In this example, the non-combustibility performance of the proposed formulations is demonstrated. The MS slurry samples, partial perlite and total perlite formulations described in the paragraphs as an example, were prepared to test ASTM E 136. These samples were assembled with thermocouples (internally and externally), placed in an oven at 750 ° C and allowed to gain heat. The maximum rise in internal and surface temperature was recorded, as well as the change in weight and duration of the flames in the samples. The results of these tests are summarized in TABLE 11-1. For the partial perlite mixture, two variants were tested: one with the regular amount of superplasticizer used in all other evaluations of this mixture and the other with a greater amount of superplasticizer. The requirements of ASTM E 136 for non-combustibility are: a) none of the recorded temperatures must rise by 30 ° C above the stabilized temperature of 750 ° C, b) weight loss will be 50% or less and c) there will be no sample flame after the first 30 seconds. All tested formulations passed the requirements of non-combustibility. However, the temperature increase was less for mixtures of perlite compared to mixtures containing only microspheres (MS). For example, the average increase in indoor temperature for the 3 samples in each set was: 19.7 ° F (-6.83 ° C) (MS), 17.3 ° F (-9.17 ° C) (perlite partial, low superplasticizer) and 15.0 ° F (-9.44 ° C) (total perlite). The better non-combustibility performance of perlite mixtures over DM mixtures may be related to the absence of organic material normally present in trace amounts in the DM (recorded as LOI). As such, perlite formulations, in particular total perlite, offer an additional advantage over this non-combustibility property. The formulations of the invention satisfy the performance requirements, in accordance with the performance requirements of the ACC 318 Acceptance Criteria of the ICC-ES and the ASTM C 1705 standard. Since the conditions under which the samples were submitted to this study were considerably more rigid than those described in ASTM C 1185, it would be expected that the mixtures investigated in this study would exhibit lower expansion values than those shown in FIG. 20 if they had been tested for ASTM C 1185 conditions.

Example 12 - High Temperature Shrinkage
[209] From panels made during the first round of production, samples were also collected for high temperature shrinkage tests. In this test, 4 "(10.2 cm) diameter samples cut with a saw from the panels were placed in a muffle at the initial ambient temperature. The oven was then allowed to heat up to 850 ° C, which normally requires about 35- 40 minutes, and then this temperature was maintained for about another 30 minutes, in a total test time of 60 to 70 minutes.The sample diameter along two perpendicular directions was measured before and after the test and the percentage change in mean diameter has been reported as "high temperature shrinkage. As a reference, a maximum shrinkage of 5% is specified for FIRECODE® Type X gypsum panels. Tests were conducted in pairs with each pair consisting of a sample of mixing MS together with a sample of mixture (total or partial) of perlite.Tests were also conducted in two separate ovens, labeled PSL and CSL, for analysis of reproducibility.The results of shrinkage and weight loss are shown n TABLE 12-1. It is generally seen that perlite mixtures exhibit greater shrinkage and weight loss compared to DM mixtures, with shrinkage and weight loss increasing as the perlite content is greater. The global shrinkage values for the perlite mixtures were within acceptable commercial variations for plasterboard panels and just as importantly, the samples remained intact and solid after the test was completed. TABLE 12-1


[210] TABLE 12-2 - High temperature shrinkage performance of samples made using partial pearlite and fully coated with structural cement panels (SCP) from TABLE 12-1 with a light cement based panel comparing the prior technique of TABLE 7-2.
5 Example 13 - Thermal Transmission
[211] From panels made during the second round of production, samples were also collected for thermal transmission tests. In this test, a thermocouple was "sandwiched" between two 4 "(10.2 cm) disks of the product in question. This set was then placed in a pre-10 muffle heated at 500 ° C for 120 minutes. The temperature record -time measured by the thermocouple was then evaluated for product performance and behavior.The temperature-time curves of these tests are shown in Figure 21 in which two replicated curves are shown for each mixture. 15 pattern in which the temperature rise decreased when the temperature reached about 125 ° C. Following this level, the temperature rose again until it finally equilibrated with the temperature of the bottom oven. extended for the duration of the plateau, thus effectively delaying the temperature increase in the sample.The extension of the delay was reinforced with an increasing amount of the expanded perlite coated in the formulation. and delay, the time required to reach 250 ° C was compared. For the various mixtures, the time required to reach 250 ° C was 35 min. for mixtures containing (MS), 39 min. (partial perlite) and 50 min. (total perlite). Perlite formulations, particularly total perlite formulations, were significantly more effective in delaying heat transmission through the sample, which would be very significant for floor and wall assemblies exposed to high temperatures. Example 14 - Small Scale Horizontal Furnace Test.
[212] Fiber-reinforced panels based on microspheres (MS) without any perlite, half perlite and half perlite (Partial) and perlite formulations without any microspheres (Total) were made for small scale horizontal oven tests. In this test, small-scale (4'x 5 ') floor sets (1.2 x 1.5 m) were constructed using 16 gauge, 9% "(23.5 cm) deep steel beams as frame members The top of the beams was covered with a layer of the panel in question, while the bottom of the beams was covered with a layer of plaster panel of 5/8 "(1.6 cm). The panels were fixed to the beams using flat-head screws with self-tapping slits with 1-5 / 8 "x 8 (4.1 x 20.3 cm) ears with 8" (20.3 cm) spacing. Three thermocouples were mounted on the top surface of the test panels to record the thermal transmission through the panel. The entire floor set was then placed in an oven that subjected the set to ASTM E 119 temperature-time conditions at its bottom, and the temperature rise was measured from thermocouples.
[213] The results of these tests are shown in FIG. 22, which shows the average temperature-time tracking for thermocouples on the panel surfaces. In particular, FIG. 22, which shows the Temperature-time curves of the MS, Partial and Total Perlite panels tested in a small-scale horizontal oven. A curve is also indicated for a test performed on a real commercial production panel (using MS only) to serve as a comparison. In general, it is observed that the perlite panels were more effective in delaying the thermal transmission through the panels, and the delay was more pronounced with the increase in the amount of perlite. This delay was manifested by a longer plateau on the 200-250 ° F (93.3121 ° C) temperature scale. To characterize the temperature-time response of the thermocouples, two time parameters were defined: the time required for the average of all thermocouples to reach 325 ° F (163 ° C); and the time required for the first individual thermocouple to reach 400 ° F (204 ° C). These times are summarized in TABLE 14-1, showing that the perlite mixtures were able to extend the time required to reach these specified temperatures. In particular, the total perlite mixtures that replaced all the ceramic microspheres on the panel, extended this time by an additional 25-30% more than the mixtures containing ceramic microspheres. This behavior reflects the behavior observed in the Thermal Transmission test (Example 13), in which the mixtures that completely replaced the ceramic microspheres with the coated expanded perlite had a greater capacity to delay the temperature increase in the material. This example again proves the advantages of the perlite formulation for high temperature condition in a real floor set.
EXAMPLE 15 - COMPARISON OF THE COMPOSITIONS OF THE FLUID PASTE MADE WITH COVERED AND NOT COATED PERLITE
[214] Among the various properties of the slurry in the fresh state, a critical property for the manufacture of SCP panels is the abatement. o Slump is a measure of the fluidity of the slurry that must be kept in a certain range, preferably 5-9 "(12.7-22.9 cm) when measured using the technique described in Example 1. The slurry with slump in this The strip is ideal for facilitating pumping and placing on the production line, good spreadability on the forming mat, good wetting of glass fibers and adequate sealing for thickness and profile control An experiment was conducted to characterize the differences in behavior between fluid pastes made with silane-coated perlites and uncoated perlites. In this example, two mixtures were prepared with identical dimensions and the only difference is the type of perlite. The weight ratio of perlite and binder was 0.115 to 1.00, while the proportion of the weight of water and binder was 0.45: 1.00, a superplasticizer of polycarboxyl ether was also used in a dosage of 0.41% by weight of cement binder. uras were made in a weight ratio of 0.061 tartaric acid and cement binder and both mixtures reached a final setting in about 45-50 minutes.
[215] Fig. 23 shows the abatement and FIG. 24 shows the density of slurries made with coated and uncoated pearls. The fluidity difference is clearly manifested in the initial slaughter, in which the mixture with coated perlite showed fluidity at the upper level of the preferred variation, while the mixture with uncoated perlite showed little fluidity. Over time, the slurry with uncoated perlite gradually became a thick, non-slurry, while the slurry with coated perlite maintained its fluidity at a reasonable level. Also over time, the slurry with uncoated perlite has undergone a greater density increase, which was due to the absorption of water in the perlites. This example demonstrated the advantages of having a water resistant coating on the perlite, in order to improve the properties of the SCP slurry for better overall manufacturing capacity. Example 16 - Water Demand for Mixtures Made with Perlite and Ceramic Microspheres.
[216] SCP formulations made with ceramic microspheres or coated perlite as fillers are fundamentally different from one another. The differences in particle density between the two fillers result in different volumetric demands of other raw materials, in order to maintain the same density and slurry properties of the product. This is further influenced by the water resistant coating on the perlite that affects the interaction between the particles and rheological behavior in general. An unexpected but important discovery of this invention is the demand for water from perlite mixtures. Example 1 described SCP formulations containing ceramic microsphere fillers that were prepared with a 0.44: 1.00 microsphere weight and binder ratio, 0.57: 1 water weight and cement binder ratio .00 and superplasticizer dosage of 0.41% by weight of cement binder (MS mixture). Different formulations containing perlite fillers were prepared with a weight ratio of perlite and binder of 0.092, 0.105 and 0.115, weight ratio of water to cement binder of 0.45: 1.00 and superplasticizer dosage of 0.39% per weight of cement binder. The focus of this discussion is the fluidity of these mixtures, which is shown by their reduction in Fig. 25. At approximately the same dosage of superplasticizer in relation to the cement binder, substantially more fluid mixtures were attainable with the perlite formulation, for the entire content shown as perlite, compared to the microsphere formulation. The water-resistant coating on the perlite particles appears to aid in the dispersion of particles in the slurry, which helps to obtain greater fluidity, in a lower ratio of water to cement binder. This result was elucidated in the previous example, which contrasted the flow characteristics between mixtures made with coated and uncoated pearls. In relation to ceramic microspheres, this means that formulations with perlite are capable of being made using a considerably lower ratio of water to binder, which in turn is advantageous for the strength and long-term durability of the matrix of cement. Those skilled in the technique of cementitious slabs, including fiber-reinforced cement structural panels, plaster and cement-plaster fiber panels, will recognize that many substitutions and modifications can be made in the previous modalities without deviating from the foundations and scope of the present one. invention.

权利要求:
Claims (10)
[0001]
1. Light, non-combustible reinforced cement panel, fire resistant to withstand transverse loads and cutting diaphragms that improve water durability and greater resistance to thermal transmission, characterized by the fact that it comprises: a continuous phase resulting from the curing of an aqueous mixture of: a compound of cementitious composition, on a dry basis, with 50 to 95% reactive powder by weight, 1 to 20% by weight of particles of expanded perlite with hydrophobic coating evenly distributed as a light charge in said continuous phase, hydrophobic-coated perlite particles with a diameter in the range of 1 to 500 microns (micrometers), an average diameter of 20 to 150 microns (micrometers) and an effective particle density (specific gravity) of less than 0.50 g / cc , 0 to 25% by weight of hollow ceramic microspheres, and 3 to 16% by weight of alkali-resistant glass fibers for uniform reinforcement of the continuous phase; wherein such reactive powder comprises: 25 to 75% by weight of alpha sulfate calcium hemihydrate, 10 to 75% by weight of hydraulic cement comprising Portland cement, 0 to 3.5% by weight of lime, and 5 to 30 % by weight of a pozzolanic asset; and wherein the panel is formed by molding the aqueous mixture; and where the panel has a density of 0.80 to 1.6 g / cc (50 to 100 pounds per cubic foot).
[0002]
2. Panel according to claim 1, particles of expanded perlite with hydrophobic coating having a diameter ranging from 1 to 500 microns (micrometers), an average diameter of 20 to 90 microns (micrometers) and an effective particle density ( specific gravity) of less than 0.30 g / cc, characterized by the fact that the particles of expanded perlite with hydrophobic coating are coated with a coating selected from a group consisting of silicones, silanes and siloxanes, in which the proportion by weight of water to reactive powder in the aqueous mixture before curing is in a weight ratio of about 0.35 to 0.65, and in which the cement panel does not contain incidentally entrained air.
[0003]
3. Panel, according to claim 1, characterized by the fact that the reactive powder comprises 55 to 75% by weight of calcium sulfate hemihydrate, 20 to 35% by weight of Portland cement, 0.75 to 1 , 25% by weight of lime, 7.5 to 20% by weight of an active pozzolanic and a superplasticizer, where such active pozzolanic is at least one member of the group consisting of silica fume, metakaolin, high-grade granulated earth slag oven, and sprayed fly ash, and the panel contains 2 to 6% by weight of the coated expanded perlite particles and 10 to 20% by weight of hollow ceramic microspheres.
[0004]
4. Panel according to claim 1, characterized in that the light load in the cementitious composition consists of 7 to 15% by weight of particles of expanded perlite with hydrophobic coating.
[0005]
5. Panel according to claim 1, characterized by the fact that a panel 19.05 mm (0.75 inches) thick, when tested according to the test method of ASTM E 661 over an extension of 406, 508 and 610 mm (16, 20 and 24 inches) in the center, has a final load capacity greater than 249 kg (550 pounds) under static load, a final load capacity greater than 182 kg (400 pounds), after loading impact and a maximum deflection impact before and after with a load of 90.9 kg (200 pounds) is less than 1.98 mm (0.078 inches), 2.39 mm (0.094 inches) and 2.74 mm (0.108 inches) of 406, 508 and 610 mm (16, 20 and 24 inch) extensions, respectively.
[0006]
6. Panel according to claim 1, characterized by the fact that such panel was formed from 70 to 93% by weight of such reactive powders, 4 to 10% by weight of such glass fibers, and 4 to 20% by weight of such a light charge comprising particles of expanded perlite with hydrophobic coating, each on a dry basis and a superplasticizer.
[0007]
7. Panel according to claim 1, characterized by the fact that the panel has one or more outer layers, in which the outer layer (s) were formed from 70 to 93% by weight of such powders reactive, 4 to 10% by weight of such glass fibers, and 4 to 20% by weight of particles of expanded perlite with hydrophobic coating, each on a dry basis.
[0008]
8. Panel according to claim 1, characterized by the fact that the reactive compound comprises about 0.2 to about 3.5% by weight of lime.
[0009]
9. Method to provide the improved fire resistance for a cutting diaphragm in a construction by improving the thermal transmission resistance of a structural cement panel in a building structure, characterized by the fact that it comprises the application of a first reinforced cementitious panel, lightweight, non-combustible, fire resistant to withstand transverse loads and cutting diaphragm having improved water durability and resistance to thermal transmission, to a metal frame element for use as a cutting diaphragm in wall systems of cutting support, in floor systems and / or in a roofing system of such construction, the first panel comprising: a continuous phase resulting from the curing of an aqueous mixture of: a compound of cementitious composition, on a dry basis, with 50 to 95% reactive powder by weight, 1 to 20% by weight of particles of expanded perlite with hydrophobic coating uniformly distributed as light charge in said co-phase Continuous, hydrophobic-coated perlite particles with a diameter in the range of about 1 to 500 microns (micrometers), an average diameter of 20 to 150 microns (micrometers) and an effective particle density (specific gravity) of less than about 0.50 g / cc, 0 to 25% by weight of hollow ceramic microspheres, and 3 to 16% by weight of alkali-resistant glass fibers for uniform reinforcement of the continuous phase; wherein such reactive powder comprises: 25 to 75% by weight of alpha sulfate calcium hemihydrate, 10 to 75% by weight of hydraulic cement comprising Portland cement, 0 to 3.5% by weight of lime, and 5 to 30 % by weight of an active pozzolanic; and in which the continuous phase is formed on a panel while it is being cured and the cured panel is cut and finished; wherein the first panel having a density of 0.8 to 1.6 g / cc (50 to 100 pounds per cubic foot); wherein the panel is formed by molding the aqueous mixture; and where a time of thermal transmission in the first panel is postponed by approximately 10% to 40% in relation to the time of thermal transmission in a second panel, having the same composition as the first panel, except that it comprises ceramic microspheres, instead of particles of expanded perlite with hydrophobic coating.
[0010]
Method according to claim 9, characterized in that the reactive compound comprises about 0.2 to about 3.5% by weight of lime.

类似技术:

---

公开号 | 公开日 | 专利标题

---

BR112013014175B1|2021-01-19|non-flammable high-performance plaster-cement compositions with enhanced water durability and thermal stability for lightweight structural reinforced cement panels

---

RU2470884C2|2012-12-27|Light cementing compositions and construction products and methods for production thereof

---

JP4562988B2|2010-10-13|Structural cladding panel

---

JP5299870B2|2013-09-25|Foundation systems and floor systems for commercial or residential buildings

---

JP2009522472A|2009-06-11|Reinforced cement shear panel

---

BRPI0908171B1|2021-08-03|METHOD FOR MANUFACTURING AN EXPLOSION RESISTANT PANEL

---

MX2007009053A|2007-09-19|Non-combustible reinforced cementitious lightweight panels and metal frame system for shear walls.

---

BRPI0519681B1|2016-08-23|non-combustible, reinforced, cementitious, lightweight panels and metal floor frame system

---

CN109177378A|2019-01-11|The fire resisting gypsum panels of low weight and density

---

BRPI0908459B1|2021-08-03|CEMENT-BASED ARMORED PANEL SYSTEM

---

JP2014500228A|2014-01-09|High performance incombustible gypsum cement composition with improved water durability and thermal stability for reinforced cementitious lightweight structural cement panels

---

BRPI0908444B1|2021-12-21|CEMENT-BASED LAMINATED ARMORED PANELS

---

MX2008008474A|2008-10-03|Reinforced cementitious shear panels

---

BRPI0908444A2|2020-10-27|cement-based armored panels

同族专利:

---

公开号 | 公开日

---

RU2013133416A|2015-01-27|

---

CA2822315A1|2012-06-28|

---

BR112013014175A2|2016-11-29|

---

MY166517A|2018-07-05|

---

JP6227723B2|2017-11-08|

---

EP2655755B1|2016-08-10|

---

AR084547A1|2013-05-22|

---

KR20140018215A|2014-02-12|

---

AU2011349661C1|2016-02-04|

---

EP2655755A1|2013-10-30|

---

KR102080667B1|2020-02-25|

---

RU2592307C2|2016-07-20|

---

CA2822315C|2020-04-07|

---

WO2012087776A1|2012-06-28|

---

CN103261539B|2016-07-06|

---

JP2017007936A|2017-01-12|

---

MX2013006682A|2013-07-29|

---

CN103261539A|2013-08-21|

---

AU2011349661A1|2013-05-02|

---

US8038790B1|2011-10-18|

---

AU2011349661B2|2015-09-24|

引用文献:

---

公开号 | 申请日 | 公开日 | 申请人 | 专利标题

---

---

US660487A|1898-08-05|1900-10-23|Gen Electric|Electric brake.|

---

US3269071A|1963-09-26|1966-08-30|United States Gypsum Co|Gypsum composition and building construction|

---

US3284980A|1964-07-15|1966-11-15|Paul E Dinkel|Hydraulic cement panel with low density core and fiber reinforced high density surface layers|

---

US3502490A|1968-01-15|1970-03-24|Frank Ware|Heat and fire-resistant plaster compositions|

---

US3869295A|1970-03-30|1975-03-04|Andrew D Bowles|Uniform lightweight concrete and plaster|

---

US3908062A|1974-01-21|1975-09-23|United States Gypsum Co|Fire-resistant, composite panel and method of making same|

---

US4369554A|1977-04-27|1983-01-25|Les Fils D'auguste Chomarat & Cie|Method for the manufacture of non-woven textile fabrics|

---

US4278468A|1979-09-10|1981-07-14|United States Gypsum Company|Gypsum fire barrier for cable fires|

---

US4304704A|1981-01-16|1981-12-08|Stonecote, Inc.|Thermal insulating material|

---

US4454267A|1982-12-20|1984-06-12|United States Gypsum Company|Lightweight joint compound|

---

US4686253A|1986-02-20|1987-08-11|United States Gypsum Company|Lightweight joint compound having improved paintability|

---

US4889747A|1988-05-02|1989-12-26|Pcr, Inc.|Hydrophobic expanded perlite compositions and process for preparing the same|

---

US5112405A|1989-01-24|1992-05-12|Sanchez Michael A|Lightweight concrete building product|

---

US5041333A|1989-02-24|1991-08-20|The Celotex Corporation|Gypsum board comprising a mineral case|

---

US5207830A|1990-03-21|1993-05-04|Venture Innovations, Inc.|Lightweight particulate cementitious materials and process for producing same|

---

WO1993004007A1|1991-08-13|1993-03-04|Boral Australian Gypsum Limited|Water-resistant building material|

---

ZA937092B|1992-10-01|1994-04-22|Plascon Tech|Building component|

---

US5718759A|1995-02-07|1998-02-17|National Gypsum Company|Cementitious gypsum-containing compositions and materials made therefrom|

---

IL113587A|1994-06-03|1999-05-09|Nat Gypsum Co|Cementitious gypsum-containing compositions and materials made therefrom|

---

US6221521B1|1998-02-03|2001-04-24|United States Gypsum Co.|Non-combustible gypsum/fiber board|

---

US6319312B1|1998-11-18|2001-11-20|Advanced Construction Materials Corp.|Strengthened, light weight wallboard and method and apparatus for making the same|

---

US6241015B1|1999-04-20|2001-06-05|Camco International, Inc.|Apparatus for remote control of wellbore fluid flow|

---

US6241815B1|1999-08-10|2001-06-05|United States Gypsum Company|Gypsum-cement system for construction materials|

---

US6620487B1|2000-11-21|2003-09-16|United States Gypsum Company|Structural sheathing panels|

---

US6902614B2|2003-03-21|2005-06-07|Slawomir Ratomski|Perlited Portland cement plaster joint compound additive with lime|

---

US7445738B2|2003-09-18|2008-11-04|United States Gypsum Company|Multi-layer process and apparatus for producing high strength fiber-reinforced structural cementitious panels|

---

US7849648B2|2004-12-30|2010-12-14|United States Gypsum Company|Non-combustible reinforced cementitious lightweight panels and metal frame system for flooring|

---

CN101166624A|2005-01-27|2008-04-23|美国石膏公司|Non-combustible reinforced cementitious lightweight panels and metal frame system for a fire wall and other fire resistive assemblies|

---

US7849649B2|2005-01-27|2010-12-14|United States Gypsum Company|Non-combustible reinforced cementitious lightweight panels and metal frame system for shear walls|

---

US7841148B2|2005-01-27|2010-11-30|United States Gypsum Company|Non-combustible reinforced cementitious lightweight panels and metal frame system for roofing|

---

US7849650B2|2005-01-27|2010-12-14|United States Gypsum Company|Non-combustible reinforced cementitious lightweight panels and metal frame system for a fire wall and other fire resistive assemblies|

---

US7845130B2|2005-12-29|2010-12-07|United States Gypsum Company|Reinforced cementitious shear panels|

---

DE102006005899B4|2006-02-09|2009-01-08|Knauf Perlite Gmbh|building board|

---

US20090085253A1|2006-03-22|2009-04-02|Leon Kruss|Construction Product|

---

US20080057318A1|2006-08-29|2008-03-06|Adzima Leonard J|Low density drywall|

---

US7381261B1|2006-12-21|2008-06-03|United States Gypsum Company|Expanded perlite annealing process|

---

US8070878B2|2007-07-05|2011-12-06|United States Gypsum Company|Lightweight cementitious compositions and building products and methods for making same|

---

US7875358B2|2007-07-06|2011-01-25|Usg Interiors, Inc.|Slurry and acoustical panel with reduced bound water|

---

WO2009007971A2|2007-07-12|2009-01-15|Zvi Barzilai|Flame- retardants for building elements|

---

US8209927B2|2007-12-20|2012-07-03|James Hardie Technology Limited|Structural fiber cement building materials|US9802866B2|2005-06-09|2017-10-31|United States Gypsum Company|Light weight gypsum board|

---

US8070895B2|2007-02-12|2011-12-06|United States Gypsum Company|Water resistant cementitious article and method for preparing same|

---

US8329308B2|2009-03-31|2012-12-11|United States Gypsum Company|Cementitious article and method for preparing the same|

---

US9169158B2|2010-04-16|2015-10-27|Cidra Corporate Services Inc.|Non-chemical air entrained admix|

---

US8230970B1|2010-12-17|2012-07-31|Concrete Innovation Services|Sound barrier wall|

---

US9296124B2|2010-12-30|2016-03-29|United States Gypsum Company|Slurry distributor with a wiping mechanism, system, and method for using same|

---

BR112013016474A2|2010-12-30|2016-09-20|United States Gypsum Co|mud distribution system and method|

---

WO2012092582A1|2010-12-30|2012-07-05|United States Gypsum Company|Slurry distributor, system and method for using same|

---

US9999989B2|2010-12-30|2018-06-19|United States Gypsum Company|Slurry distributor with a profiling mechanism, system, and method for using same|

---

US10076853B2|2010-12-30|2018-09-18|United States Gypsum Company|Slurry distributor, system, and method for using same|

---

US9745224B2|2011-10-07|2017-08-29|Boral Ip HoldingsPty Limited|Inorganic polymer/organic polymer composites and methods of making same|

---

AR088523A1|2011-10-24|2014-06-18|United States Gypsum Co|MULTIPLE SLEEVE DOWNLOAD BOOT TO DISTRIBUTE A MILK|

---

MY171362A|2011-10-24|2019-10-10|United States Gypsum Co|Flow splitter for slurry distribution system|

---

CA2851533C|2011-10-24|2020-01-14|United States Gypsum Company|Multi-piece mold and method of making slurry distributor|

---

US8864901B2|2011-11-30|2014-10-21|Boral Ip HoldingsPty Limited|Calcium sulfoaluminate cement-containing inorganic polymer compositions and methods of making same|

---

CA2863577A1|2012-02-17|2013-08-22|United States Gypsum Company|Gypsum products with high efficiency heat sink additives|

---

US9255454B2|2012-03-09|2016-02-09|Halliburton Energy Services, Inc.|Set-delayed cement compositions comprising pumice and associated methods|

---

US9856167B2|2012-03-09|2018-01-02|Halliburton Energy Services, Inc.|Mitigation of contamination effects in set-delayed cement compositions comprising pumice and hydrated lime|

---

US9580638B2|2012-03-09|2017-02-28|Halliburton Energy Services, Inc.|Use of synthetic smectite in set-delayed cement compositions|

---

US9790132B2|2012-03-09|2017-10-17|Halliburton Energy Services, Inc.|Set-delayed cement compositions comprising pumice and associated methods|

---

US9227872B2|2012-03-09|2016-01-05|Halliburton Energy Services, Inc.|Cement set activators for set-delayed cement compositions and associated methods|

---

US9505972B2|2012-03-09|2016-11-29|Halliburton Energy Services, Inc.|Lost circulation treatment fluids comprising pumice and associated methods|

---

US10082001B2|2012-03-09|2018-09-25|Halliburton Energy Services, Inc.|Cement set activators for cement compositions and associated methods|

---

US9328281B2|2012-03-09|2016-05-03|Halliburton Energy Services, Inc.|Foaming of set-delayed cement compositions comprising pumice and hydrated lime|

---

US8851173B2|2012-03-09|2014-10-07|Halliburton Energy Services, Inc.|Set-delayed cement compositions comprising pumice and associated methods|

---

US10202751B2|2012-03-09|2019-02-12|Halliburton Energy Services, Inc.|Set-delayed cement compositions comprising pumice and associated methods|

---

US9212534B2|2012-03-09|2015-12-15|Halliburton Energy Services, Inc.|Plugging and abandoning a well using a set-delayed cement composition comprising pumice|

---

US9534165B2|2012-03-09|2017-01-03|Halliburton Energy Services, Inc.|Settable compositions and methods of use|

---

US9371712B2|2012-03-09|2016-06-21|Halliburton Energy Services, Inc.|Cement set activators for set-delayed cement compositions and associated methods|

---

US9328583B2|2012-03-09|2016-05-03|Halliburton Energy Services, Inc.|Set-delayed cement compositions comprising pumice and associated methods|

---

US9255031B2|2012-03-09|2016-02-09|Halliburton Energy Services, Inc.|Two-part set-delayed cement compositions|

---

US10195764B2|2012-03-09|2019-02-05|Halliburton Energy Services, Inc.|Set-delayed cement compositions comprising pumice and associated methods|

---

US9890082B2|2012-04-27|2018-02-13|United States Gypsum Company|Dimensionally stable geopolymer composition and method|

---

US9321681B2|2012-04-27|2016-04-26|United States Gypsum Company|Dimensionally stable geopolymer compositions and method|

---

MX2012007356A|2012-06-22|2013-12-23|Martin Escamilla Gonzalez|Coating and sealing composition for various applications in plastic arts and the construction industry.|

---

US9540810B2|2012-10-23|2017-01-10|United States Gypsum Company|Pregelatinized starch with mid-range viscosity, and product, slurry and methods related thereto|

---

US10399899B2|2012-10-23|2019-09-03|United States Gypsum Company|Pregelatinized starch with mid-range viscosity, and product, slurry and methods related thereto|

---

US9828441B2|2012-10-23|2017-11-28|United States Gypsum Company|Method of preparing pregelatinized, partially hydrolyzed starch and related methods and products|

---

US9649662B2|2012-11-21|2017-05-16|Zks, Llc|Seamless reinforced concrete structural insulated panel|

---

US10781140B2|2013-03-14|2020-09-22|Solidia Technologies, Inc.|Method and apparatus for the curing of composite material by control over rate limiting steps in water removal|

---

US10336036B2|2013-03-15|2019-07-02|United States Gypsum Company|Cementitious article comprising hydrophobic finish|

---

US8937118B2|2013-05-10|2015-01-20|Ahmed Maher Ghalayini|Building materials made from recycled items|

---

EP2996998B1|2013-05-16|2020-02-12|BNZ Materials, Inc.|Refractory castables with hydrophobic aggregates|

---

US8915997B2|2013-05-16|2014-12-23|Navs, Llc|Durable concrete and method for producing the same|

---

MX2016001654A|2013-09-09|2016-05-02|Halliburton Energy Services Inc|Activation of set-delayed cement compositions by retarder exchange.|

---

US8974925B1|2013-10-15|2015-03-10|United States Gypsum Company|Gypsum board|

---

US10059033B2|2014-02-18|2018-08-28|United States Gypsum Company|Cementitious slurry mixing and dispensing system with pulser assembly and method for using same|

---

US9975808B2|2014-05-02|2018-05-22|United States Gypsum Company|Ultra-light cementitious compositions and related methods|

---

US20150379462A1|2014-06-27|2015-12-31|Pregis Innovative Packaging Llc|Protective packaging system consumable resupply system|

---

US9593044B2|2014-11-17|2017-03-14|Georgia-Pacific Gypsum Llc|Gypsum panels, cores, and methods for the manufacture thereof|

---

EP3067177A1|2015-03-09|2016-09-14|Etex Engineering NV|Process and apparatus for making a fiber cement sheet|

---

WO2016142365A1|2015-03-09|2016-09-15|Uzin Utz Ag|Chemical formulation for construction|

---

US10155692B2|2015-03-13|2018-12-18|United States Gypsum Company|Hydrophobic finish compositions with extended flow time retention and building products made thereof|

---

CA2980948C|2015-03-27|2018-10-02|Magnesium Oxide Board Corporation Pty Ltd|A construction board and a method of manufacture|

---

CN104947845A|2015-05-11|2015-09-30|上海承雨新材料科技有限公司|Full-magnesium-oxysulfate cement light thermal insulation bearing wall board|

---

US9624131B1|2015-10-22|2017-04-18|United States Gypsum Company|Freeze-thaw durable geopolymer compositions and methods for making same|

---

PE20181476A1|2016-02-19|2018-09-13|Etex Building Performance Int Sas|PLASTER PANEL|

---

US10392308B2|2016-04-04|2019-08-27|Futong Cui|Fire retardant construction materials|

---

CA2965761A1|2016-05-04|2017-11-04|Alireza Molaei Manesh|Gypsum cement composition and articles formed thereof|

---

US9670096B1|2016-08-04|2017-06-06|Geopolymer Solutions LLC|High strength, density controlled cold fusion concrete cementitious spray applied fireproofing|

---

US10981294B2|2016-08-05|2021-04-20|United States Gypsum Company|Headbox and forming station for fiber-reinforced cementitious panel production|

---

US11224990B2|2016-08-05|2022-01-18|United States Gypsum Company|Continuous methods of making fiber reinforced concrete panels|

---

US11173629B2|2016-08-05|2021-11-16|United States Gypsum Company|Continuous mixer and method of mixing reinforcing fibers with cementitious materials|

---

US10272399B2|2016-08-05|2019-04-30|United States Gypsum Company|Method for producing fiber reinforced cementitious slurry using a multi-stage continuous mixer|

---

US10577797B2|2016-09-26|2020-03-03|Cellblock Fcs, Llc|Fire containment panel|

---

WO2018112561A1|2016-12-20|2018-06-28|Инсомат Ллс|Method and device for producing hydraulically bound building materials|

---

US10450494B2|2018-01-17|2019-10-22|Bj Services, Llc|Cement slurries for well bores|

---

US20200139674A1|2018-11-01|2020-05-07|United States Gypsum Company|Water barrier exterior sheathing panel|

---

EA202191704A1|2018-12-20|2021-11-16|Кнауф Гипс Кг|BUILDING MATERIAL BASED ON GYPSUM|

---

US11180412B2|2019-04-17|2021-11-23|United States Gypsum Company|Aluminate-enhanced type I Portland cements with short setting times and cement boards produced therefrom|

---

CN111866671B|2019-04-24|2021-11-16|歌尔股份有限公司|Vibrating diaphragm for miniature sound generating device and miniature sound generating device|

---

CN110218067B|2019-06-18|2022-01-04|孙德民|Efficient heat insulation plate and preparation method thereof|

---

US10954162B1|2019-09-24|2021-03-23|Geopolymer Solutions, LLC|Protective coating|

---

US20210189737A1|2019-12-23|2021-06-24|United States Gypsum Company|Apparatus and process with a vibratory angled plate and/or fixed horizontal plate for forming fiber-reinforced cementitious panels with controlled thickness|

---

CN112094077A|2020-03-31|2020-12-18|同济大学|Ecological planting plate for surface water storage and preparation method thereof|

---

CN112315357A|2020-10-31|2021-02-05|湖南人文科技学院|Artificial bathroom deck and preparation method thereof|

---

CN113601693B|2021-10-11|2021-12-28|佛山市东鹏陶瓷有限公司|Process technology for preparing strengthened and toughened rock plate by layering distribution|

法律状态:
2018-12-18| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

---

2019-08-27| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

---

2020-11-17| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

---

2021-01-19| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 16/12/2011, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

---

申请号 | 申请日 | 专利标题

---

US12/977,801|2010-12-23|

---

US12/977,801|US8038790B1|2010-12-23|2010-12-23|High performance non-combustible gypsum-cement compositions with enhanced water durability and thermal stability for reinforced cementitious lightweight structural cement panels|

---

PCT/US2011/065333|WO2012087776A1|2010-12-23|2011-12-16|High performance non-combustible gypsum-cement compositions with enhanced water durability and thermal stability for reinforced cementitious lightweight structural cement panels|

---