US20070261364A1 - Mould resistant sandwich panel - Google Patents
Mould resistant sandwich panel Download PDFInfo
- Publication number
- US20070261364A1 US20070261364A1 US11/747,166 US74716607A US2007261364A1 US 20070261364 A1 US20070261364 A1 US 20070261364A1 US 74716607 A US74716607 A US 74716607A US 2007261364 A1 US2007261364 A1 US 2007261364A1
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- United States
- Prior art keywords
- concrete
- foam
- mineral
- apertures
- sandwich panel
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
- E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
Definitions
- the present invention relates to a sandwich panel that is resistant to mould.
- the mould resistant sandwich panel includes a plurality of frame members having opposed faces and opposed sides. Mineral board sheets are secured to the opposed sides of the frame members, thereby creating a plurality of interior compartments. One of mineral foam, concrete foam or concrete is used to fill each of the interior compartments.
- FIG. 1 is a side plan view, in section of a mould resistant sandwich panel.
- FIG. 2 is a top plan view of a mould resistant sandwich panel
- FIG. 3 is a front plan view of a frame member.
- FIG. 4 is a front plan view of an alternative frame member.
- FIG. 5 is a front plan view of another alternative frame member.
- FIG. 6 is a perspective view of elongate components installed in the frame members.
- FIG. 7 is a detailed, exploded perspective view of a reinforcing mesh installed in the mould resistant sandwich panel.
- FIG. 8 is a side plan view, in section of a mould resistant sandwich panel with a window installed.
- FIG. 9 is a top plan view of a corner of a mould resistant sandwich panel.
- FIG. 10 is a detailed side plan view of a mould resistant sandwich panel attached to a ceiling.
- FIG. 11 is a detailed side plan view of a mould resistant sandwich panel attached to a floor.
- mould resistant sandwich panel 10 generally identified by reference numeral 10 .
- mould resistant sandwich panel 10 includes a plurality of frame members 12 having opposed faces 14 and opposed sides 16 .
- Mineral board sheets 18 are secured to opposed sides 16 of frame members 12 , (either vertically as shown or horizontally) by fasteners 19 (as seen in FIG. 2 ), thereby creating a plurality of interior compartments 20 .
- Mineral board sheets 18 may be composed of, for example, calcium silicate, magnesium, cement, or other such materials. Referring to These compartments 20 are then filled with mineral foam 22 . While mineral foam is used as the embodiment in this document, this could easily be other suitable substances, such as concrete foam or concrete. Referring to FIG.
- flow apertures 24 and aligned apertures 26 extend through frame members 12 between opposed faces 14 .
- Flow apertures 24 must be of a sufficient size to permit mineral foam 22 to flow between compartments 20 when filling compartments 20 , such that it is not necessary to fill each compartment 20 individually.
- the size of flow apertures 24 may vary depending on the material, for example, they may have to be larger if cement is used instead of mineral foam 22 .
- frame members 12 may not have any apertures, or referring to FIG. 5 , frame members 12 may only have aligned apertures 26 .
- FIG. 6 a combination of different frame members 12 may be used, where frame members 12 without flow apertures 24 are used for the ends of panel 10 .
- aligned apertures 26 which may be knockout apertures, are used to allow one or more elongate components 28 , such as electrical conduit, plumbing pipe, or rebar used to reinforce the mineral foam 22 . These components 28 are positioned within aligned apertures prior to filling compartments 20 with mineral foam 22 .
- reinforcing mesh 30 instead of using rebar to reinforce mineral foam 22 , it may be preferable to use a reinforcing mesh 30 positioned between mineral board sheets 18 . If reinforcing mesh 30 is used, spacer elements 32 may be included to ensure there is a space between reinforcing mesh 30 from mineral board sheets 18 . Examples of materials used for reinforcing mesh 30 that have given desirable results include basalt and fibreglass.
- the frame 34 of a window is attached to frame members 12 by fasteners 19 .
- Frame members 12 are spaced to accommodate frame 34 , and shorter frame members 36 are provided above and below to ensure panel 10 is sufficiently strong.
- inner and outer corner reinforcements 38 and 40 are provided to ensure panel 10 is sufficiently strong when filling with mineral foam 22 .
- Accommodation must also be made to secure panel 10 to a floor, and to secure a roof or ceiling on top of panel 10 .
- anchors 42 are provided that pass through a plate 44 .
- Plate 44 may have knockout apertures (not shown) similar to frame members 12 to allow, for example, plumbing pipe or electrical conduit, to pass through.
- anchors 42 are partially embedded within mineral foam 22 to allow a roof or ceiling 46 to be secured to it.
- anchors 42 are partially embedded in a floor 48 , which may be concrete, and are also held by mineral foam 22 in compartments 20 .
- a mould resistant sandwich panel 10 is assembled by providing frame members 12 having opposed faces 14 and opposed sides 16 .
- reinforcing mesh 30 is used, it is attached to opposed sides 16 , and spacer elements 32 are also installed over reinforcing mesh 30 wherever there is a frame member 12 .
- Mineral board sheets 18 are then secured to opposed sides 16 of frame members 12 over spacer elements 32 and reinforcing mesh 30 to create a plurality of interior compartments 20 as shown in FIG. 2 .
- aligned apertures 26 are then knocked out, and components 28 such as electrical conduit, plumbing pipe or rebar are extended through apertures 26 .
- interior compartments 20 are then filled with mineral foam 22 , with flow apertures allowing mineral foam 22 to flow between compartments 20 .
- Mineral foam, concrete foam and concrete all provide a higher resistance to fire and a more structurally sound structure during a disaster event, such as fire or flood, than traditional methods of constructing.
- a disaster event such as fire or flood
- mineral foam and concrete foam are preferred because of the higher insulative value and lighter weight as compared to concrete.
- mould resistant sandwich panel 10 not using paper or other organic products to construct mould resistant sandwich panel 10 means that, in addition to mould resistance, damage from insects will also be reduced.
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Building Environments (AREA)
Abstract
A mould resistant sandwich panel includes a plurality of frame members having opposed faces and opposed sides. Mineral board sheets secured to the opposed sides of the frame members, thereby creating a plurality of interior compartments. Either mineral foam, concrete foam or concrete is used to fill each of the interior compartments.
Description
- The present invention relates to a sandwich panel that is resistant to mould.
- After the flooding of New Orleans, many building that were structurally sound had to be destroyed due to mould infestation. Many materials commonly used in building construction, such as drywall paper, insulation paper, and wood, serve as nutrients for mould.
- There is therefore provided a mould resistant sandwich panel. The mould resistant sandwich panel includes a plurality of frame members having opposed faces and opposed sides. Mineral board sheets are secured to the opposed sides of the frame members, thereby creating a plurality of interior compartments. One of mineral foam, concrete foam or concrete is used to fill each of the interior compartments.
- Other aspects will be apparent from the claims, which are incorporated by reference.
- These and other features of the invention will become more apparent from the following description in which reference is made to the appended drawings, the drawings are for the purpose of illustration only and are not intended to in any way limit the scope of the invention to the particular embodiment or embodiments shown, wherein:
-
FIG. 1 is a side plan view, in section of a mould resistant sandwich panel. -
FIG. 2 is a top plan view of a mould resistant sandwich panel -
FIG. 3 is a front plan view of a frame member. -
FIG. 4 is a front plan view of an alternative frame member. -
FIG. 5 is a front plan view of another alternative frame member. -
FIG. 6 is a perspective view of elongate components installed in the frame members. -
FIG. 7 is a detailed, exploded perspective view of a reinforcing mesh installed in the mould resistant sandwich panel. -
FIG. 8 is a side plan view, in section of a mould resistant sandwich panel with a window installed. -
FIG. 9 is a top plan view of a corner of a mould resistant sandwich panel. -
FIG. 10 is a detailed side plan view of a mould resistant sandwich panel attached to a ceiling. -
FIG. 11 is a detailed side plan view of a mould resistant sandwich panel attached to a floor. - The preferred embodiment, a mould resistant sandwich panel generally identified by
reference numeral 10, will now be described with reference toFIG. 1 through 11. - Structure and Relationship of Parts:
- Referring to
FIGS. 1 and 2 , mouldresistant sandwich panel 10 includes a plurality offrame members 12 having opposedfaces 14 and opposedsides 16.Mineral board sheets 18 are secured to opposedsides 16 offrame members 12, (either vertically as shown or horizontally) by fasteners 19 (as seen inFIG. 2 ), thereby creating a plurality ofinterior compartments 20.Mineral board sheets 18 may be composed of, for example, calcium silicate, magnesium, cement, or other such materials. Referring to Thesecompartments 20 are then filled withmineral foam 22. While mineral foam is used as the embodiment in this document, this could easily be other suitable substances, such as concrete foam or concrete. Referring toFIG. 3 , two types of apertures:flow apertures 24 and alignedapertures 26 extend throughframe members 12 betweenopposed faces 14.Flow apertures 24 must be of a sufficient size to permitmineral foam 22 to flow betweencompartments 20 when fillingcompartments 20, such that it is not necessary to fill eachcompartment 20 individually. The size offlow apertures 24 may vary depending on the material, for example, they may have to be larger if cement is used instead ofmineral foam 22. Referring toFIG. 4 ,frame members 12 may not have any apertures, or referring toFIG. 5 ,frame members 12 may only have alignedapertures 26. Referring toFIG. 6 , a combination ofdifferent frame members 12 may be used, whereframe members 12 withoutflow apertures 24 are used for the ends ofpanel 10. Depending upon the viscosity ofmineral foam 22, it may still be necessary to “top up”compartments 20 to completely fill them. Referring toFIG. 6 , alignedapertures 26, which may be knockout apertures, are used to allow one or moreelongate components 28, such as electrical conduit, plumbing pipe, or rebar used to reinforce themineral foam 22. Thesecomponents 28 are positioned within aligned apertures prior to fillingcompartments 20 withmineral foam 22. - Referring to
FIG. 7 , instead of using rebar to reinforcemineral foam 22, it may be preferable to use a reinforcingmesh 30 positioned betweenmineral board sheets 18. If reinforcingmesh 30 is used,spacer elements 32 may be included to ensure there is a space between reinforcingmesh 30 frommineral board sheets 18. Examples of materials used for reinforcingmesh 30 that have given desirable results include basalt and fibreglass. - In constructing a structure, it may also be necessary to provide windows or doors in
panel 10. Referring toFIG. 8 , theframe 34 of a window is attached toframe members 12 byfasteners 19.Frame members 12 are spaced to accommodateframe 34, andshorter frame members 36 are provided above and below to ensurepanel 10 is sufficiently strong. Referring toFIG. 9 , when a corner is installed, inner andouter corner reinforcements panel 10 is sufficiently strong when filling withmineral foam 22. Accommodation must also be made to securepanel 10 to a floor, and to secure a roof or ceiling on top ofpanel 10. Referring toFIGS. 10 and 11 ,anchors 42 are provided that pass through aplate 44.Plate 44 may have knockout apertures (not shown) similar toframe members 12 to allow, for example, plumbing pipe or electrical conduit, to pass through. Referring toFIG. 10 ,anchors 42 are partially embedded withinmineral foam 22 to allow a roof orceiling 46 to be secured to it. Referring toFIG. 11 ,anchors 42 are partially embedded in afloor 48, which may be concrete, and are also held bymineral foam 22 incompartments 20. - Operation:
- Referring now to
FIGS. 1 and 2 , a mouldresistant sandwich panel 10 is assembled by providingframe members 12 having opposedfaces 14 and opposedsides 16. Referring toFIG. 7 , if reinforcingmesh 30 is used, it is attached to opposedsides 16, andspacer elements 32 are also installed over reinforcingmesh 30 wherever there is aframe member 12.Mineral board sheets 18 are then secured to opposedsides 16 offrame members 12 overspacer elements 32 and reinforcingmesh 30 to create a plurality ofinterior compartments 20 as shown inFIG. 2 . Referring toFIG. 6 , alignedapertures 26 are then knocked out, andcomponents 28 such as electrical conduit, plumbing pipe or rebar are extended throughapertures 26. Referring again toFIG. 2 ,interior compartments 20 are then filled withmineral foam 22, with flow apertures allowingmineral foam 22 to flow betweencompartments 20. - Advantages:
- Mineral foam, concrete foam and concrete all provide a higher resistance to fire and a more structurally sound structure during a disaster event, such as fire or flood, than traditional methods of constructing. However, while concrete will work, mineral foam and concrete foam are preferred because of the higher insulative value and lighter weight as compared to concrete.
- Also, not using paper or other organic products to construct mould
resistant sandwich panel 10 means that, in addition to mould resistance, damage from insects will also be reduced. - One of the disadvantages of using mineral foam, concrete foam or concrete is the lack of tensile strength inherent in these materials. Thus, by providing reinforcing
mesh 30, and/orcomponents 28 such as electrical conduit, plumbing pipe and rebar, the tensile strength of concrete is improved, and can be made adequately strong to be used in structures. - In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one of the elements.
- It will be apparent to one skilled in the art that modifications may be made to the illustrated embodiment without departing from the spirit and scope of the invention as hereinafter defined in the Claims.
Claims (15)
1. A mould resistant sandwich panel, comprising:
a plurality of frame members having opposed faces and opposed sides;
mineral board sheets secured to the opposed sides of the frame members, thereby creating a plurality of interior compartments; and
one of mineral foam, concrete foam or concrete filling each of the interior compartments.
2. The mould resistant sandwich panel of claim 1 , wherein apertures extend through the frame members between the opposed faces.
3. The mould resistant sandwich panel of claim 2 , wherein the apertures are knockout apertures.
4. The mould resistant sandwich panel of claim 2 , wherein the apertures are adapted to receive electrical conduit.
5. The mould resistant sandwich panel of claim 2 , wherein the apertures are adapted to receive plumbing pipe.
6. The mould resistant sandwich panel of claim 2 , wherein the apertures are adapted to allow the one of mineral foam, concrete foam or concrete to flow between interior compartments when filling the interior compartments with the one of mineral foam, concrete foam or concrete.
7. The mould resistant sandwich panel of claim 2 , wherein the apertures are adapted to receive rebar to reinforce the one of mineral foam, concrete foam or concrete.
8. The mould resistant sandwich panel of claim 1 , wherein a reinforcing mesh is positioned between the mineral board sheets to reinforce the one of mineral foam, concrete foam or concrete.
9. The mould resistant sandwich panel of claim 8 , wherein spacer elements are included to space the reinforcing mesh from the mineral board sheets.
10. A mould resistant sandwich panel comprising:
a plurality of frame members having opposed faces and opposed sides, the frame members comprising flow apertures and aligned apertures;
mineral board sheets secured to the opposed sides of the frame members, thereby creating a plurality of interior compartments;
one of mineral foam, concrete foam or concrete filling each of the interior compartments, the flow apertures adapted to allow the one of mineral foam, concrete foam or concrete to flow between the interior compartments during filling;
a reinforcing mesh positioned between the mineral board sheets to reinforce the one of mineral foam, concrete foam or concrete;
spacer elements to space the reinforcing mesh from the mineral board sheets; and
at least one of electrical conduit and plumbing pipe extending through the aligned apertures.
11. A method of fabricating a mould resistant sandwich panel, the method comprising the steps of:
providing a plurality of frame members having opposed faces and opposed sides;
securing mineral board sheets to the opposed sides of frame members to create a plurality of interior compartments; and
filling the interior compartments with one of mineral foam, concrete foam or concrete.
12. The method of claim 11 , wherein providing a plurality of frame members comprises providing a plurality of frame members having apertures that extend between the opposed faces.
13. The method of claim 12 , wherein filling the interior compartments comprises the one of mineral foam, concrete foam or concrete flowing between compartments through the apertures.
14. The method of claim 12 , further comprising the step of extending at least one of electrical conduit, plumbing pipe, and rebar through the apertures prior to filling the interior compartments with the one of mineral foam, concrete foam or concrete.
15. The method of claim 11 , further comprising the step of positioning a reinforcing mesh within the interior compartments prior to filling the interior compartments with the one of mineral foam, concrete foam or concrete.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA2,548,968 | 2006-05-11 | ||
CA002548968A CA2548968A1 (en) | 2006-05-11 | 2006-05-11 | Mould resistant sandwich panel |
Publications (1)
Publication Number | Publication Date |
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US20070261364A1 true US20070261364A1 (en) | 2007-11-15 |
Family
ID=38683805
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/747,166 Abandoned US20070261364A1 (en) | 2006-05-11 | 2007-05-10 | Mould resistant sandwich panel |
Country Status (2)
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US (1) | US20070261364A1 (en) |
CA (1) | CA2548968A1 (en) |
Cited By (4)
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US20070234675A1 (en) * | 2006-03-17 | 2007-10-11 | Panel Resources, Inc. | Lightweight man-made board |
US20090193739A1 (en) * | 2008-02-01 | 2009-08-06 | Advanced Basement Products | Modular Basement Finishing System |
KR102214700B1 (en) * | 2020-06-22 | 2021-02-10 | 한밭대학교 산학협력단 | Variable side formwork |
US11118342B1 (en) * | 2019-09-20 | 2021-09-14 | Ajn Investment & Development 2008 Ltd | Wall panel system and method of use |
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US20020092251A1 (en) * | 1999-02-09 | 2002-07-18 | Timothy Alvaro | Insulated concrete wall construction method and apparatus |
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US6269608B1 (en) * | 1999-11-04 | 2001-08-07 | William H. Porter | Structural insulated panels for use with 2X stick construction |
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US20040067352A1 (en) * | 2002-10-04 | 2004-04-08 | Hagerman Joseph W. | Rigid composite building materials and assemblies utilizing porous and non-porous rigid foamed core materials |
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US20060265985A1 (en) * | 2005-05-25 | 2006-11-30 | Nichols Michael P | Insulated wall panel for building construction and method and apparatus for manufacture thereof |
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US20070234675A1 (en) * | 2006-03-17 | 2007-10-11 | Panel Resources, Inc. | Lightweight man-made board |
US20090193739A1 (en) * | 2008-02-01 | 2009-08-06 | Advanced Basement Products | Modular Basement Finishing System |
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US11118342B1 (en) * | 2019-09-20 | 2021-09-14 | Ajn Investment & Development 2008 Ltd | Wall panel system and method of use |
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