Ecologically Sustainable Structural Panel
An ecologically sustainable structural panel. The structural panel comprises of a unique gage frame, expanding foam, and ecologically sustainable exterior sheathing boards. The ecologically sustainable structural panel is fireproof, water proof, mold proof, asbestos free, impact resistant, moisture resistant, and bacteria resistant. The ecologically sustainable structural panel is also capable of withstanding winds of up to 150 miles per hour due to unique operative connections between male junctions, female junctions, L-junctions, anchors, and the utilization of pins instead of screws.
The inventor of the present invention has been in the construction industry for 15 years and has a background in engineering. During his period of working in the construction industry he identified a problem with existing structural panels.
One of the major problems with the structural panels presently used is that they use Expanded Polystyrene (hereinafter referred to as “EPS”) materials during fabrications. EPS materials are used to insulate the panels. However, EPS materials are toxic and highly flammable. The present invention uses expandable foam from the amino resin family, consisting of phenol, urea, and melamine coupled with an aldehyde to obviate the toxicity normally present in EPS when fabricating structural panels.
Another danger of using EPS material based structural panels is that when they catch on fire, the EPS material structural makeup collapses, thereby making any structure constructed using the structural panels structurally deficient. The present invention uses an amino resin foam material to insulate the structural panels. This amino resin foam has a high melting point, is resistance to moisture, and is resistance to bacteria. The amino resin foam increases the structural makeup of structural panels using this material.
The inventor first identified the toxic and structural elements that were problematic in the structural panel industry in 2003 and worked diligently to find a solution to the problem. The solution consisted of finding a material that would have a high melting point and that at the same time would not be toxic upon being ignited.
The inventor's research also lead him to discover that structural panel sheathing boards could be fabricated from two chief ingredients: magnesium oxide, which is a fireproofing material, and gypsum, which provides good finishing qualities and cementing characteristics for structural panels. The sheathing boards were rigid enough to act as structural paneling and provided the further advantage of being recyclable.
The above findings caused the inventor first to create sheathing boards from magnesium oxide and gypsum. He then procured expandable foam composed of amino furin resins. He then filled the hollow space between two sheathing boards with the expandable foam and finally used pins to attach the sheathing boards. This produced an ecologically sustainable structural panel that was fire proof, mold proof, moisture resistant, bacteria resistant, and free of asbestos, and metals. However, the structural panel still lacked the structural integrity to withstand strong winds and sudden impacts.
The inventor further realized that the best way to achieve structural integrity was to provide a frame for the structural panel. He recalled that L-junctions were efficacious in providing resistance to vertical forces such as hurricane strength winds. He also knew that male and female junctions would reinforce each other and provide the synergy to create a strong overall frame. After trial and error, he created galvanized steel stud members having a substantially U-shaped cross-section. The stud members slid into each other to create a hollow rectangular stud member. The inventor then connected the stud members into a frame by utilizing male junctions, female junctions, L-junctions and pins. He then anchored the frame to the floor surface with an industrial grade 5 ⅛×4 inch anchor screw. The inventor next filled in the hollow space between the rectangular stud member with the expandable foam. Finally, he sandwiched the frame between two sheathing boards to create his ecologically sustainable structural panel.
Structural panels have been used in the construction industry in the past, yet none with the present characteristics of the present invention. See U.S. Pat. Nos.: 4,765,105; 4,578,909; 2008/0115442; 2009/0056255; and 3,797,190.
For the foregoing reasons, there is a need for an ecologically sustainable structural panel that is fireproof, water proof, mold proof, asbestos free, impact resistant, moisture resistant, bacteria resistant, and that can withstand winds of up to 150 miles per hour.
SUMMARYThe present invention is directed to an ecologically sustainable structural panel that is fireproof, water proof, mold proof, asbestos free, impact resistant, moisture resistant, and bacteria resistant. The ecologically sustainable structural panel is also capable of withstanding winds of up to 150 miles per hour due to unique operative connections between male junctions, female junctions, L-junctions, anchors, and the utilization of pins instead of screws.
The present invention is an ecologically sustainable structural panel. The structural integrity of the structural panel comes from its unique gage frame and expanding foam. The gage frame is composed of galvanized steel stud members designed to fit together for maximum structural reinforcement. The stud members, which have a U-shaped cross-section are constructed to slide into each other, forming a hollow and substantially rectangular stud member. Male junctions, female junctions, L-junctions, pins, and anchors located at the ends of the stud members connect to form secure connections. Electrical pvc pipes are also embedded into the gage frame to increase structural integrity. Since the gage frame is made of galvanized steel, it is fireproof. A unique expanding foam composed of an amino resin fills a cavity located inside the hollow and substantially rectangular stud member and provides desirable properties for the structural panel such as recyclability, fire resistance, mold resistance, impact resistant, moisture resistance, and bacteria resistance. Exterior sheathing boards composed chiefly of gypsum and magnesium oxide sandwich the gage frame to form the complete structural panel. The sheathing boards are also recyclable, fire proof, mold proof, impact resistant, moisture resistant, bacteria resistant, and do not contain metals, or asbestos. Furthermore, the complete structural panel is prefabricated; prefabrication reduces the time normally spent installing structural panels.
An object of the present invention is to provide a structural panel that is fireproof, water proof, mold proof, asbestos free, impact resistant, moisture resistant, bacteria resistant, and that can withstand winds of up to 150 miles per hour.
Another object of the present invention is to reduce construction costs by providing a prefabricated structural panel, and using pins instead of screws for operative connectivity.
Yet another object of the present invention is to provide a ecologically sustainable, recyclable structural panel free of organic solvents, oils, and toxins.
These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and drawings where:
One embodiment of the ecologically sustainable structural panel 200 is seen in
The ecologically sustainable structural panel 200 comprises of at least two exterior sheathing boards 10 comprised of a mixture of magnesium oxide and gypsum, whereby a rigid surface will be provided. The ecologically sustainable structural panel 200 also comprises of a gage frame 20 for providing structural integrity. The gage frame 20 comprises of a plurality of stud members 30. Each stud member 30 defines at least one end 35. Each stud member 30 further defines at least one junction 37 at the ends 35 of the stud member for structural reinforcement. The stud member 30 ends 35 utilize either a male junction 70 for structural reinforcement, a female junction 80 for structural reinforcement, or an L-junction 90 for structural reinforcement, whereby the stud members 30 connect to each other using the male junctions 70, the female junctions 80, and the L-junctions 90 located at their two ends 35, along with a plurality of pins 100. Each stud member 30 further defines a substantially U-shaped cross-section 40. Each U-shaped cross-section 40 defines a small variance in width so that when two opposing stud members 30 slide together, they form a hollow and substantially rectangular stud member 50. Each hollow and substantially rectangular stud member 50 defines an opening 60 along its longitudinal axis suitable for injecting an amorphous material inside a cavity in the opening 60 of the hollow and substantially rectangular stud member 50. The ecologically sustainable structural panel 200 further comprises of an expandable foam 110 composed of an amino resin, the amino resin comprises of phenol, urea, melamine, and aldehyde. The expandable foam 110 fills the cavity inside the opening 60 of the hollow and substantially rectangular stud member 50. The ecologically sustainable structural panel 200 further comprises of a plurality of anchors 120 for securing the gage frame 20 to a floor surface 130. After the expandable foam 110 fills the cavity in the hollow and substantially rectangular stud member 50, the exterior sheathing boards 10 sandwich the gage frame 20 to form a completed ecologically sustainable structural panel 200.
In an embodiment of the present invention, the gage frame 20 is made of galvanized steel.
In a further embodiment of the present invention, half inch electrical pvc pipes are embedded into the gage frame 20 for structural reinforcement.
In yet another embodiment of the present invention, the expandable foam 110 is water proof, fire proof, mold proof, does not contain metals, or asbestos.
An advantage of the present invention is that the exterior sheathing boards 10 are ecologically sustainable, recyclable, and contain no organic solvents, oils, or toxins.
Another advantage of the present invention is that it is prefabricated and ready to install on site, whereby construction costs are reduced by at least 30%.
Another advantage of the present invention is that it comprises of an expandable foam 110 that is water proof, fire proof, mold proof, and does not contain metals, or asbestos.
Yet another advantage of the present invention is that the ends of the stud members 30 are held down by pins 100 rather than screws, whereby construction time and costs are significantly reduced.
Yet another advantage of the present invention is that the gage frame 20 is made of galvanized steel rather than wood, whereby the risk of fire is eliminated.
Yet another advantage of the present invention is that it is Florida hurricane tested, STC-Rated 53-54, and ready for all 2007 ICC criteria.
Although the present invention has been described in considerable detail in reference to preferred versions, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein.
Claims
1. An ecologically sustainable structural panel, comprising:
- at least two exterior sheathing boards comprising of a mixture of magnesium oxide and gypsum;
- a gage frame, the gage frame defines a plurality of stud members, each stud member defines two ends, each stud member further defines at least one junction at the end of the stud member for structural reinforcement, each stud member further defines a substantially U-shaped cross-section, the substantially U-shaped cross-section has a small variance in width so that two of the opposing stud members slide together to form a hollow and substantially rectangular stud member, the hollow and substantially rectangular stud member defines an opening along its longitudinal axis suitable for injecting an amorphous material, and a plurality of pins for structural reinforcement, whereby the stud members connect to each other using the junctions and the pins;
- an expandable foam comprising an amino resin, the amino resin comprising phenol, urea, melamine, and aldehyde, the expandable foam is inserted into the hollow and substantially rectangular stud member; and
- a plurality of anchors for securing the gage frame to a floor surface.
2. The ecologically sustainable structural panel of claim 1, wherein the junctions are either male, female, or L-shaped.
3. The ecologically sustainable structural panel of claim 2, wherein the gage frame is made of galvanized steel.
4. The ecologically sustainable structural panel of claim 3, further comprise of at least one electrical pipe that embeds into the gage frame for structural reinforcement.
5. The ecologically sustainable structural panel of claim 4, wherein each electrical pipe is a half inch pvc pipe.
6. The ecologically sustainable structural panel of claim 5, wherein the expandable foam is ecologically sustainable, recyclable, water proof, fire proof, mold proof, does not contain metals, and does not contain asbestos.
7. The ecologically sustainable structural panel of claim 6, wherein the anchor dimensions are about five and an eighth by about four inches.
Type: Application
Filed: Oct 29, 2011
Publication Date: May 2, 2013
Inventor: Alfredo Rodriguez (Miami, FL)
Application Number: 13/284,873
International Classification: E04B 2/34 (20060101); E04C 2/20 (20060101); E04C 2/52 (20060101);
