LAMINATE BUILDING MATERIALS AND METHODS OF MAKING AND INSTALLING THE SAME

Abstract

Magnesium oxide cement sheathing is laminated to plywood, OSB, wood, steel, other building products or other substrates to enhance fire, structural and sound performance of the substrate to meet new and more stringent fire codes while also providing water, insect, mold and rot protection. Further, the magnesium oxide cement board laminated to a foam core enhances fire performance and mold and rot protection over that of the foam core alone. The magnesium oxide laminate is used in wall, floor and roof assemblies to meet or exceed performance as specified in the building codes.

Description

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57.

BACKGROUND

Building departments in the US recognize that increased urban density elevates the risk of fire spreading to adjacent buildings. In addition, increased development has led to the construction of many buildings in wildfire-urban interface zones. The result is stronger mandates for fire codes that require the use of non-combustible and fire rated materials in new and retrofit construction. Requirements focus on exterior walls, roofs, and floor structures in various construction applications.

Fire codes focus on flame spread, smoke generation, and duration of material performance during a fire. The codes determine materials performance requirements as well as wall assembly requirements necessary to meet several classes of construction. Typical wood framed walls and roofs utilize plywood or oriented strand board (OSB) as the exterior sheathing or roofing material. In many applications, codes require structure exteriors that are non-combustible.

One response to the fire codes has been to coat wood based sheathing with an intumescent substance that increases fire performance. Another has been to introduce fire resistant additives in the manufacture of OSB or plywood. Neither of these approached work very well.

Builders sometimes use fire resistant materials, such as gypsum based sheathing, cementatious siding, and a sufficient thickness of stucco, brick, or stone veneer, in wall and roof assemblies where performance is specified in the building codes. Such materials are not structural so they are added in addition to structural sheathing which now must also be protected from water penetration behind the fire barrier. These are layered, costly, and time consuming assemblies.

SUMMARY

Embodiments describe the lamination of Magnesium Oxide (MgO) cement based boards or sheathing to building materials. In an embodiment, the MgO cement boards are structural and comprise fiberglass-reinforced magnesium oxide cement boards. Boards/sheathing made with MgO cement are noncombustible and generate no smoke when exposed to flame. Unlike OSB, MgO cement boards or sheathing do not support mold or mildew, are insect-proof, and are water, freeze/thaw, and impact resistant. The MgO cement boards have low thermal conductivity, reflect heat radiation and help isolate the wood and other building materials from the heat source.

They can be laminated to wood-based and other products to substantially improve fire performance. Further, the MgO laminate improves the mold and rot protection of the substrate, and eliminates many of the steps required to protect wood or other substrate, which, in turn, reduces building costs. By modifying the chemical mixture, ingredients, and thickness, MgO cement boards can also be engineered to increase the structural performance of an MgO laminated board. The MgO laminate is an ideal solution since the OSB or plywood is already approved for structural performance under the prescriptive building codes and the MgO provides the fire performance required to meet new codes.

In another embodiment, the MgO cement boards can be laminated to foam materials to substantially improve fire, water, rot, and mold performance. In addition, by using MgO laminated products, many other building products can be manufactured with the added performance the MgO provides.

Certain embodiments disclose a building material. The building material comprises a magnesium oxide (MgO) board, a substrate, and an adhesive layer interposed, applied, or located between the MgO board and the substrate, where the MgO board is laminated to the substrate with the adhesive layer to form a laminate. In an embodiment, the laminate comprises a flame spread rating of about zero according to ASTM E-84. In another embodiment, the laminate comprises a smoke generation rating of about zero according to ASTM E-84. In another embodiment, the laminate has an airborne sound reduction index of 31 db according to testing done by the China Building Materials Center for Quality Supervision. In a further embodiment, the laminate is noncombustible according to ASTM E-136. In a yet further embodiment, the building material further comprises a finishing material directly applied to the laminate without additional fire or moisture protection, where the finishing material comprises stucco, siding, brick, decorative stone, molding and the like.

In an embodiment, the substrate comprises an oriented strand board (OSB), where the laminate comprises a greater resistance to fungal growth than the OSB, a greater structural strength than the OSB, a greater resistance to moisture than the OSB. In another embodiment, the substrate comprises a foam core material. In a further embodiment, the adhesive layer is selected from the group consisting of polyvinyl acetate (PVA), water-based polymeric adhesives, solvent-based adhesives, thermostat adhesives, modified starches, liquid moisture cure adhesives, and polyurethane.

In an embodiment, the substrate comprises a wooden joist including an upper flange, a lower flange, and a web interposed between the upper and the lower flanges. In another embodiment, the MgO board is laminated to at least one side of the web. In a further embodiment, the MgO board is laminated to both sides of the web. In a yet further embodiment, the MgO board encases the wooden joist. In an embodiment, the MgO board is laminated to the upper flange and the lower flange along the length of the joist. In another embodiment, the joist is a floor and roofing I-joist.

According to some embodiments, a method to fabricate a building material is disclosed. The method comprises providing a magnesium oxide (MgO) board, providing a substrate, and interposing an adhesive layer between the MgO board and the substrate to laminate the MgO board to the substrate with the adhesive layer to form a laminate.

For purposes of summarizing the disclosure, certain aspects, advantages and novel features of the inventions have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a perspective view, partially cut away, of a laminated panel, according to certain embodiments.

FIG. 1B illustrates a cross-sectional view of the laminated panel of FIG. 1A, according to certain embodiments.

FIG. 2 is a flow chart illustrating a process to manufacture a laminated building material, according to certain embodiments.

FIG. 3 illustrates a typical wooden joist, according to certain embodiments.

FIG. 4 illustrates a typical wooden I-joist, according to certain embodiments.

FIG. 5 illustrates a laminated fire resistant joist, according to certain embodiments.

FIG. 6 illustrates a laminated fire resistant I-joist, according to certain embodiments.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The features of the systems and methods will now be described with reference to the drawings summarized above. Throughout the drawings, reference numbers are re-used to indicate correspondence between referenced elements. The drawings, associated descriptions, and specific implementation are provided to illustrate embodiments of the inventions and not to limit the scope of the disclosure.

FIG. 1A illustrates a perspective view, partially cut away, of a laminated panel or laminate 100. The laminated panel 100 comprises a first layer 102 and a second layer or substrate 104. FIG. 1B illustrates a cross-sectional view of the laminate 100 and shows the first layer 102 and the second layer 104 may be laminated together using an adhesive 106 to create a single piece laminate composite. The laminate 100 can take any form necessary, including, but not limited to panels, sheets, skins, boards, or the like.

The substrate 104 comprises any of a plurality of building materials, such as, for example, OSB, plywood, wood, steel, metal, foam, foam cores, gypsum based sheathing, and the like. Examples of foam and/or foam cores are polyurethane, polyester, closed cell polyester, extruded polystyrene, ester, latex rubber, neoprene, vinyl, closed cell sponge rubber, open cell sponge rubber, cellulose, polystyrene, polyvinylchloride PVC.

In an embodiment, the adhesive 106 comprises a water-based polymeric adhesive, such as a latex-based adhesive, or the like. Other examples of the adhesive 106 are, but not limited to, polyvinyl acetate (PVA), solvent-based adhesives, thermostat adhesives, natural polymers such as modified starches, liquid moisture cure or reactive hot melt adhesives such as polyurethane, heat or fire resistant adhesives, and the like.

In an embodiment, the first layer 102 comprises Magnesium Oxide (MgO) cement based boards or sheathing. In another embodiment, the MgO cement boards 102 are structural and comprise fiberglass-reinforced MgO cement boards. In a further embodiment, the layer 102 comprises MagBoard™, the properties of which are described below in Tables A-D. All testing was done in accordance to the International Accreditation Service (IAS) ISO Guidelines.

In an embodiment, the thickness of the MgO laminate 100 ranges from approximately 9 mm to approximately 42 mm and preferably from approximately 12 mm to approximately 24 mm. In an embodiment, the thickness of the first layer 102 ranges from approximately 3 mm to approximately 18 mm and preferably from approximately 6 mm to approximately 12 mm. In an embodiment, the thickness of the substrate 104 ranges from approximately 3 mm to approximately 24 mm, more preferably from approximately 6 mm to approximately 18 mm.

Another example of an MgO laminated building product 100 is the MgO/foam laminate 100 which can be used in the construction of recreational vehicles (RVs), such as for interior and exterior wall partitions. Typically the RV industry uses a 3 mm wood based plywood product laminated to extruded polystyrene (XPS) foam, which does not perform well in fires, rots easily, and supports mold. Replacing the wood based substrate with the MgO/foam laminate 100 enhances the long term performance of the wall partitions and provides enhanced fire, rot, mold, sound and insect resistance over that of the foam alone.

In an embodiment, the MgO/foam laminate comprises MgO cement based sheathing 102 laminated to a foam core substrate 104. In an embodiment, MgO sheathing 102 is laminated to the foam core 104 using the adhesive 106. In some embodiments, the MgO cement based sheathing 102 comprises MagBoard™ and the foam core 104 comprises extruded polystyrene foam. In a preferred embodiment, the MgO/foam laminate 100 comprises an approximately 3 mm thick sheet of MagBoard™ laminated to approximately one inch of extruded polystyrene foam. In other embodiments, the MgO board 102 can be more or less than 3 mm, the substrate 104 can be more or less than one inch, and the substrate 104 can comprise one or more of polyurethane, polyester, closed cell polyester, ester, latex rubber, neoprene, vinyl, closed cell sponge rubber, open cell sponge rubber, cellulose, polystyrene, polyvinylchloride PVC, and the like.

Tests and Test Results

Table A provides the test and performance requirements, the test standards, the requirements, and the test results for physical property testing of approximately 12 mm or ½ inch thick MagBoard™.

TABLE A
PHYSICAL PROPERTIES TESTING (12 mm ½ inch)
TEST AND
PERFORMANCE
REQUIREMENTS	TEST STANDARD	REQUIREMENTS	TEST RESULTS
Non	ASTM E136-09a	No flaming under test	Rated as Non Combustible
Combustible		parameters
Surface Burning	ASTM E84	5 smoke 10 flame	0 smoke 0 flame
Characteristics		contribution	contribution
Flexural Strength	ICC-ES AC386	min 580 psi both	dry parallel 1576 psi
	ASTM C1185-08	wet and dry	dry perpendicular 2,251 psi
			wet parallel 1,291 psi,
			wet perpendicular 2,041 psi
Freeze Thaw	ASTM C666	No disintegration after	Pass
Cycling		25 Cycles
Dimension And	ASTM C1186		Pass
Tolerance
Moisture	ICC-ES AC386	Accepted dimensional	0.02%,
Movement	ASTM C1185-08:	tolerance from 30 to 90%
		humidity
Water	ICC-ES AC386		29.80%
Absorption	ASTM C1185-08
Water Vapor	ASTM E96/E96M-05		2.46 perms
Transmission
Compression	ICC-ES AC386	>1250 psi <.05 inch	Pass 1736 PSI
Indentation	ASTM D2394
Nail Head Pull	ICC-ES AC386	>90 lb.	292 lb-pass
Through	ASTM D1037-99:
Lateral Nail	ICC-ES AC378	>90 lb.	Pass
Resistance	ASTM D1037-99:		¼″ dry 115 lb, wet 41 lb
			⅜″ dry 196 lb, wet 113 lb,
			½″ dry 261 lb, wet 157 lb,
			¾″ dry 337 lb, wet 209 lb
Falling Ball	ICC-ES AC386	no damage at 12″ drop	Pass
Impact	ASTM D1037-99:

Table B provides the test and performance requirements, the test standards, the requirements, and the test results for assembly and panel structural testing of approximately 12 mm or ½ inch thick MagBoard.

TABLE B
ASSEMBLY and PANEL STRUCTURAL TESTING (12 mm ½ inch)
TEST AND
PERFORMANCE
REQUIREMENTS	TEST STANDARD	REQUIREMENTS	TEST RESULTS
Structural	ASTM E72-05	Transverse Load	Positive pressure 260 psf
2 × 6 WoodFrame		(Assembly exceeded test	recorded
		frame capabilities)	Negative Pressure 210.7 psf
		Wet Racking Shear	5270 lbs 658.8 plf
		⅛ in deflection	1483 lbs 185.4 plf
Structural	ASTM E72-05	Transverse Load,	Positive pressure 237 psf
2 × 4 SteelFrame		Wet Racking Shear	Negative Pressure 102 psf
			7494 lbs 936.67 plf
Structural	ASTM E72-02	Ultimate Transverse 0	161 psf
Insulated panel	ASTME564	bearing
4 ft × 8 ft × 6.5 inch		Allowable Transverse 0	44.8 psf
		bearing
		Ultimate Transverse bearing	178.5 psf
		Allowable Transverse	59.5 psf
		bearing
		Ultimate Axial load	55,741 lbs
		Allowable Axial load	4645 lbs
		Ultimate Shear	10,869 lbs
		Allowable Shear	453 plf
Structural	ASTM E72-02	Ultimate Transverse 0	185.7 psf
Insulated Panel	ASTM E564	bearing
4 ft × 8 ft × 8.5 inch		Allowable Transverse 0	61.9 psf
		bearing
		Ultimate Transverse bearing	182.6 psf
		Allowable transverse bearing	65.7 psf
		Ultimate Axial load	66,246 lbs
		Allowable Axial load	5,521 lbs
		Ultimate Shear	10,063 lbs
		Allowable Shear	377 plf
Structural	ASTM E72-02	Ultimate Transverse	182 psf
Insulated Panel	ASTM E564	Axial load	43,247 lbs
4 ft × 9 ft × 6.5 inch
Structural	ASTM E72-02	Ultimate Transverse	224 psf
Insulated Panel	ASTM E564	Axial load	51,888 lbs
4 ft × 9 ft × 8.25 inch

Table C provides the test and performance requirements, the test standards, the requirements, and the test results for assembly and panel fire testing of approximately 12 mm or ½ inch thick MagBoard.

TABLE C
ASSEMBLY and PANEL FIRE TESTING (12 mm ½ inch)
TEST AND
PERFORMANCE	TEST		TEST
REQUIREMENTS	STANDARD	REQUIREMENTS	RESULTS
Fire Rated	E119-08a	Per assembly*	2 Hour Fire
Assembly			Endurance
2 × 6 Wood Frame			Rating
Fire Rated	E119-08a	Per assembly*	2 Hour Fire
Assembly			Endurance
2 × 4 Steel Frame			Rating
6.5 inch Structural	E84-10b	Per assembly	0 Flame spread
Insulated Panel			0 Smoke
			generation
6.5 inch Structural	E119-10a	Per assembly*	2 hour fire
Insulated Panel			endurance
			rating

Table D provides the test and performance requirements, the test standards, the requirements, and the test results of wet area underlayment and backer board testing of 6 mm or ¼ inch thick MagBoard.

TABLE D
WET AREA UNDERLAYMENT AND BACKER BOARD TESTS (6 mm 1/4 inch)
TEST AND
PERFORMANCE
REQUIREMENTS	TEST STANDARD	REQUIREMENTS	TEST RESULTS
Dimensional	ASTM C1185	Length (in.) =/− .25	Pass
Tolerances		Width (in.) =/− .25	Pass
		Thickness (in.) =/− .25	Pass
		Square Straightness (in.) =/− .25	Pass
		Edge Straightness (in.) =/− .25	Pass
Flexural Strength	ASTM C1185	>1450 PSI	2,854 psi
Fastener Pull	ASTM D1037	>.90	Pass
Through
Compressive	ASTM C1325	>1250 PSI	Pass
Strength	ASTM D3295
Surface Burning	ASTM E84	5 smoke 10 flame	0 smoke 0 flame
Characteristics		contribution	contribution
Non Combustible	ASTM E136-09a	No flaming under test	Rated as Non Combustible
		parameters
Mold and Mildew	ASTM G21	Non Nutrient	Pass Non Nutrient
	ASTM D3273
Fungus Testing	ASTM D3273	Pass	No evidence of fungal
			growth ASTM rating of 10
Linear Variation	ASTM D1037	Less than or equal to .07%	0.07%
With Change In
Moisture Content
Moisture	ASTM C1185	Less than or equal to .02%	0.07%
Movement %
Linear Change
Modulus of	ASTM D1037	398,900 psi	456,100 psi
Elasticity	ANSI 208.1-99
Modulus of	ASTM D1037	2,393 psi	3,071 psi
Rupture	ANSI 208.1-99
Modulus of	ASTM D1037	retain min of 50% MOR	Pass
Rupture Retention	ANSI 208.1-99
Weight	ASTM 1037	Weight per Sq. Ft.	1.4 lbs.
Thickness Swell	ASTM 1037	24 hour thickness swell	3.5%-4%
7 day Shear Bond	ANSI A 118.1	50 PSI at 7 day curing	98 psi
Strength
Portland Cement
7 Day Shear Bond	ANSI 136.1	50 PSI at 7 day curing	189 psi
Strength
Organic Mortar
Latex Portland	ANSI A 118.4	50 PSI at 7 day curing	201 psi
Cement Mortar
Organic Mortar	ANSI 136.1	50 PSI at 7 day curing	Pass
Humidified	ICC-ES AC386	<.3125 in. (ceiling)	.053 in.
Deflection	ICC-ES AC378
	ASTM C473-07:

Table E provides the test and performance requirements, the test standards, the requirements, and the test results of sound testing of 12 mm or ½ inch thick MagBoard™ according to testing done by the China Building Materials Center for Quality Supervision.

Fire and Combustibility Testing

Of particular note are the results of the fire performance testing. When evaluating building materials for fire safety, many factors including ignition temperature, smoke toxicity and flame-spread are considered. Flame-and smoke spread and combustibility, used to describe the surface burning characteristics of building materials, are among the most tested fire performance properties of a material. The best known test for developing a flame and smoke spread rating is the American Society for Testing and Materials (ASTM) Test Method E-84, commonly known as the tunnel test. The tunnel test measures how far and how fast flames spread across the surface of the test sample. In this test, a sample of the material 20 inches wide and 25 feet long, is installed as ceiling of a test chamber, and exposed to a gas flame at one end. The resulting flame spread rating (FSR) is expressed as a number on a continuous scale where inorganic reinforced cement board is 0 and red oak is 100. The scale is divided into three classes. The most commonly used flame-spread classifications are: Class I or A, with a 0-25 FSR; Class II or B with a 26-75 FSR; and Class III or C with a 76-200 FSR.

Table A includes the ASTM E-84 test results for 12 mm MagBoard™; Table C includes the ASTM E-84 test results for a 6.5 inch Structural Insulated Panel of 12 mm MagBoard™; and Table D includes ASTM E-84 test results for 6 mm MagBoard™. In each case, MagBoard™ has a flame spread rating of approximately zero, has a smoke generation rating of approximately zero, and is a Class A material.

In contrast, OSB has a flame spread rating of approximately 148 and a smoke generation rating of approximately 137, and is a Class C material. Since the ASTM E-84 test is a surface burning test, the laminate 100 would have the same or similar test results as the MagBoard test results. Thus, the MgO/OSB laminate 100 has significantly improved surface burning and smoke generation characteristics to that of the OSB substrate 104.

The best known test for combustibility is the American Society for Testing and Materials (ASTM) Test Method E-136. The ASTM E-136 test measures the behavior of materials in a vertical tube furnace at 750° C. Table D includes the ASTM E-136-09a test results for 6 mm MagBoard. The test results indicate no flaming under the test parameters and the MagBoard is rated as non-combustible.

In contrast, OSB is combustible. Even with cementatious or other fire retardant coatings, OSB is not rated as non-combustible. Thus, the MgO/OSB laminate 100 has significantly improved non-combustibility characteristics to that of the OSB substrate 104.

The ASTM E-119 test measures the hourly fire resistance rating for an assembly using construction materials. An hourly fire rating is the time a wall assembly can be expected to contain a fire and, in the case of load-bearing walls, continue to provide some structural support. This test is not a requirement for a material to be used in non-combustible construction, but can be a requirement based on the construction and occupancy types for the building. Table C includes the ASTM E-119-08a test results for a 2×6 wood frame assembly constructed with approximately 12 mm MagBoard and a 2×4 steel frame assembly constructed with approximately 12 mm MagBoard. Table C further includes the ASTM E-119-10a test results for a 6.5 inch structural insulated panel (SIP) constructed with approximately 12 mm MagBoard. In each test, the MagBoard assembly achieved at least a 2 hour fire endurance rating.

In contrast, a partition wall assembly constructed with 15 mm OSB has a fire rating of approximately 14 minutes. Thus, the MgO/OSB laminate 100 has significantly improved fire rating characteristics to that of the OSB substrate 104.

Thus, by laminating Magboard 102 to a substrate 104, the fire performance of a wall assembly can be greatly improved. Further, by varying the thickness of the Magboard layer 102, the laminate 100 can be manufactured to have a range of fire performances, including flame spread, combustibility, and fire rating, to meet current and future building codes. Building products and or assemblies laminated with the MgO layer 102 can be manufactured to have a range of fire performances, including flame spread, combustibility, and fire rating, to meet current and future building codes.

Mold/Rot Testing

ASTM D3273 tests for the resistance to growth of mold on the surface interior coatings in an environmental chamber and ASTM G21 determines the effect of fungi on the properties of the tested material. As indicated in Table D, MagBoard is a non-nutrient for mold and mildew according to ASTM G21 and ASTM D3272 testing. Further, there is no evidence of fungal growth according ASTM D3273 testing. MagBoard has an ASTM D3273 rating of 10, indicating no disfigurement by particulate matter.

In contrast, structural wood products, such as OSB, lumber, plywood, and the like, share the same basic chemical composition, namely a matrix of cellulose and lignin, which support fungi, mold and mildew growth. Often antifungal agents are applied to OSB to reduce the risk of toxic mold growth. Further, during construction of buildings, additional layers are added to protect OSB and other wood products from moisture, a major cause of mold growth. This adds additional construction costs.

The MgO board layer 102 provides fungi, mold, and mildew resistance which is the same as or similar to the MagBoard ASTM G21 and D3273 test results to the laminate 100. Thus, the MgO/OSB laminate 100 has significantly improved fungi, mold, and mildew resistance characteristics to those of the OSB substrate 104 alone.

Structural Testing

ASTM E72-05 tests the strength of panels for building construction. Table B indicates the ASTM E72-05 test results for assemblies and panels comprising 12 mm MagBoard. The MagBoard assembly and panel test results are consistent with the ASTM E72-05 test results for OBS, SIPs, or other building material assemblies and panels.

Sound Testing

The Airborne Sound Reduction Index is used to measure the level of sound insulation provided by a structure such as a wall, window, door, or ventilator. This is a laboratory measurement, which uses knowledge of the relative sizes of the rooms in the test suite, and the reverberation time in the receiving room, and the known level of noise which can pass between the rooms in the suite by other routes (flanking) plus the size of the test sample to produce a very accurate and repeatable measurement of the performance of the sampled material or construction. Table E indicates the Airborne Sound Reduction Index for 12 mm Magboard™ is approximately 31 dB. Thus by laminating Magboard™ to the substrate 104, an improvement in the sound performance of wall assemblies can be achieved.

Vapor Retardant

Moisture or water vapor can move into building cavities in three ways: with air currents; by diffusion through materials; and by heat transfer. Of these three, air movement typically accounts for more than 98% of all water vapor movement in building cavities. Material that slow the rate of vapor diffusion into the thermal envelope of a structure, such as the wall, ceiling, and floor assemblies of buildings are referred to as vapor retarders. Vapor retarders have varying degrees of permeability and have a moisture vapor transmission rate that is established by standard test methods. Permeability can be reported in perms, a measure of the rate of transfer of water vapor through a material where 1.0 US perm=1.0 grain/square-foot•hour•inch of mercury ≈57 SI perm=57 ng/s•m2•Pa.

Adhesives act as vapor retarders and each adhesive has a different vapor retardant property. In certain embodiments, the adhesive 106 in the laminate 100 is a vapor retarder. The laminate 100 comprising the adhesive 106 comprises a structural vapor diffusion retarder, which retards the diffusion of water vapor or other moisture through wall, ceilings and floor assemblies of buildings, as well as having other structural and fire resistant properties. [0049] Building codes change often, and typically become stricter to enhance safety and performance of the building project. Advantageously, the MgO laminate 100 can meet or out perform these performance requirements. For example, the thickness of the MgO board 102 and/or the thickness and/or material of the substrate 104 can be varied to meet ever increasing design requirements or changing building codes. In another example, the adhesive 106 used in fabricating the laminate 100 can be varied to provide laminates 100 that meet varying permeances of vapor retards specified in the building codes.

FIG. 2 is a flow chart illustrating a process 200 to manufacture a laminated building material, such as the laminate 100. At step 202, the process 200 provides sheathing, such as the MgO cement based sheathing 102 and at step 202 the process 200 provides the substrate 104.

At step 206, the adhesive 106 is applied. In an embodiment, a roller-coater process applies the adhesive. Other methods of applying the adhesive 106 comprise rolling by hand, painting, spraying, and the like. The adhesive is preferably applied evenly over the surface. The wet film weight of the applied adhesive 106 when measured with a standard scale ranges from approximately 22 grams per square foot to approximately 30 grams per square foot, and preferably is not less than approximately 26 grams per square foot and not more than approximately 30 grams per square foot. In an embodiment, the adhesive 106 is applied to the top layer 102. In another embodiment, the adhesive 106 is applied to the substrate 104. The layer 102, 104 without the adhesive 106 is placed on top of the layer 102, 104 coated with the adhesive 106.

In another embodiment, at step 206, the process 200 uses a roll press lamination process with a suitable pressure sensitive adhesive to laminate the top layer 102 to the substrate 104.

At step 208, the process 200 cures the laminate under pressure. In an embodiment, the laminate 100 is place in a press and cured under a pressure of approximately 10 psi to approximately 14 psi, and preferably approximately 12 psi. In one embodiment, the adhesive 106 comprises a latex-based adhesive and the curing time ranges from about 20 minutes to about 30 minutes. In addition, the curing time may vary with the temperature of the curing environment, such that less time may needed to cure the laminate 100 when it is hot, and more time may be needed when it is cool. In other embodiments, other adhesives 106 are used, and the curing time varies based on the adhesive and the temperature.

At step 210, the process 200 optionally applies a finish to the laminate 100. For example, the edges of the laminate 100 could be sealed to restrict water absorption by painting the edges with paint or other sealer, the surface of the laminate 100 could be painted, covered with stucco, or the like, a wood grain or other texture could be formed in the laminate 100 or formed during the fabrication of the MgO board 102, another layer, such as a wood layer with a wood grain finish could be laminated to the laminate 100, and the like. The finishing step 210 can be performed during the fabrication of the laminate 100, at a constructions site, or at any other time.

Installation

The laminate 100 may be installed on interior or exterior walls. The laminate can be installed using a compatible adhesive, mechanical fasteners, such as screws, nails, and the like, or a combination. The laminate 100 may be applied to wood or steel framing.

Building Product Embodiments

In addition, by using MgO laminated products, many other building products can be made with the added performance of the MgO layer 102. One example of an MgO laminated building product is a laminated fire resistant joist. FIG. 3 illustrates typical framing construction 300 comprising traditional wooden joists 302. In an embodiment, the joists 302 comprise timber, plywood, OSB, and the like. The joists 302 above one or more studs are being used as roofing joists and the joists 302 below a floor 306 are being used as flooring joists, in the illustrated example in FIG. 3.

FIG. 4 illustrates a typical wooden I-joist 400 comprising a web or vertical element 404 inserted in the grooves of upper and lower flanges or horizontal elements 402a, 402b, respectively. In an embodiment, the joist 400 comprises a Truss Joist I-beam™ (™). In an embodiment, the flanges 402 and the web 404 comprise wood, plywood, OSB, and the like.

FIG. 5 illustrates a laminated fire resistant joist 500 comprising the joist 300 laminated with MgO cement based boards 502, 504, 506, 508, 510. In the illustrated embodiment, MgO board 502 is laminated to a first side of the joist 300; MgO board 504 is laminated to a second side of the joist 300; MgO board 506 is laminated to a third or top side of the joist 300, MgO board 508 is laminated to a fourth or bottom side of the joist 300; MgO board 510 is laminated to a first end of the joist 300; and MgO board 512 is laminated to a second end of the joist 300. In an embodiment, the MgO boards 502-512 encompass, surround, enclose, encase or envelop the joist 300.

In an embodiment, boards 502-512 comprise Magnesium Oxide (MgO) cement based boards or sheathing. In another embodiment, the MgO cement boards 502-512 are structural and comprise fiberglass-reinforced MgO cement boards. In a further embodiment, the boards 502-512 comprise MagBoard™.

In an embodiment, the fire resistant joist 500 is a fire resistant floor and roof joist. The joist 500 encases the wooden joist 300 and provides the fire, insect, mold, mildew, and rot protection associated with the MgO boards.

FIG. 6 illustrates a laminated fire resistant joist 600. The joist 600 comprises the joist 400 laminated with MgO cement based boards. In the illustrated embodiment, an upper surface of the upper flange 402a and a lower surface of the lower flange 402b are laminated with the MgO cement based boards 602a, 602b, respectively, and the first and second sides of the web 404 are laminated with the MgO cement based boards 604a, 604b, respectively. In a further embodiment, the front end and the back end of the joist 400 are laminated with MgO boards cement based boards 606a and 606b (not illustrated), respectively. In an embodiment, the MgO boards 602-606 encompass, surround, enclose, encase, or envelop the joist 400.

In an embodiment, boards 602-606 comprise Magnesium Oxide (MgO) cement based boards or sheathing. In another embodiment, the MgO cement boards 602-606 are structural and comprise fiberglass-reinforced MgO cement boards. In a further embodiment, the boards 602-606 comprise MagBoard™.

Laminated joists 500, 600 comprise similar flame spread and smoke generation numbers as those for MagBoard included on Tables A, C, and D. As discussed above, the flame spread for the laminated joist 500, 600 is approximately zero and the smoke generation number is approximately zero. Similarly, floor and roofing joists made of unprotected OSB comprise similar flame spread and smoke generation numbers as standard OSB, such as a flame spread rating of approximately 148 and a smoke generation rating of approximately 137.

Thus, the laminated joist 500, 600 has substantially increased the flame resistance and smoke spread characteristics of joists constructed of OSB or a similar material alone. The resulting laminated joist 500, 600 comprises a fire resistant joist having the enhanced fire and structural performance associated with the MgO cement board to meet new and more stringent fire codes, while also providing water, insect, and mold and rot protection.

While specific embodiments of, and examples for, the invention are described above for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those ordinary skilled in the relevant art will recognize. For example, other substrates, such as metal, foam, fiberglass reinforced plastic, plywood and the like, can be laminated to magnesium oxide boards to provide the laminate with enhanced characteristics provided by the magnesium oxide board. In another example, other OSB or wood building products, such as melamine, particle board, high density chip board, and the like can be laminated with magnesium oxide board to enhance the laminated products with the characteristics of the magnesium oxide board.

Terminology

The above detailed description of certain embodiments is not intended to be exhaustive or to limit the invention to the precise form disclosed above. While specific embodiments of, and examples for, the invention are described above for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those ordinary skilled in the relevant art will recognize. For example, while processes or blocks are presented in a given order, alternative embodiments may perform routines having steps, or employ systems having blocks, in a different order, and some processes or blocks may be deleted, moved, added, subdivided, combined, and/or modified. Each of these processes or blocks may be implemented in a variety of different ways. Also, while processes or blocks are at times shown as being performed in series, these processes or blocks may instead be performed in parallel, or may be performed at different times.

Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” The words “proportional to”, as generally used herein refer to being based at least in part on. The words “coupled” or connected”, as generally used herein, refer to two or more elements that may be either directly connected, or connected by way of one or more intermediate elements. Additionally, the words “herein,” “above,” “below,” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. Where the context permits, words in the above Detailed Description using the singular or plural number may also include the plural or singular number respectively. The word “or” in reference to a list of two or more items, that word covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list.

Moreover, conditional language used herein, such as, among others, “can,” “could,” “might,” “may,” “e.g.,” “for example,” “such as” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or states. Thus, such conditional language is not generally intended to imply that features, elements and/or states are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without author input or prompting, whether these features, elements and/or states are included or are to be performed in any particular embodiment.

The teachings of the invention provided herein can be applied to other systems, not necessarily the systems described above. The elements and acts of the various embodiments described above can be combined to provide further embodiments.

While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosure. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure.

Claims

1. A building material comprising:

a magnesium oxide (MgO) board;

a substrate; and

an adhesive layer interposed between the MgO board and the substrate, the MgO board laminated to the substrate with the adhesive layer to form a laminate.

2. The building material of claim 1 wherein the laminate comprises a flame spread rating of about zero according to ASTM E-84.

3. The building material of claim 1 wherein the laminate comprises a smoke generation rating of about zero according to ASTM E-84.

4. The building material of claim 1 wherein the laminate is noncombustible according to ASTM E-136.

5. The building material of claim 1 further comprising a finishing material directly applied to the laminate without additional fire or moisture protection.

6. The building material of claim 1 wherein the substrate comprises an oriented strand board (OSB).

7. The building material of claim 6 wherein the laminate comprises at least one of a greater resistance to fungal growth than the OSB, a greater structural strength than the OSB, and a greater resistance to moisture than the OSB.

8. The building material of claim 1 wherein the substrate comprises a foam core material.

9. The building material of claim 1 wherein the adhesive layer is selected from the group consisting of polyvinyl acetate (PVA), water-based polymeric adhesives, solvent-based adhesives, thermostat adhesives, modified starches, liquid moisture cure adhesives, and polyurethane.

10. The building material of claim 1 wherein the adhesive layer is associated with a permeability and the laminate comprises a structural vapor diffusion retarder.

11. The building material of claim 1 wherein the substrate comprises a joist including an upper flange, a lower flange, and a web interposed between the upper and the lower flanges.

12. The building material of claim 11 wherein the MgO board is laminated to at least one side of the web.

13. The building material of claim 11 wherein the MgO board is laminated to both sides of the web.

14. The building material of claim 11 wherein the MgO board is laminated to the upper flange and the lower flange along the length of the joist.

15. The building material of claim 11 wherein the MgO board encases the joist.

16. The building material of claim 1 wherein the MgO board forms at least one surface of a laminate to increase the fire rating of a wall assembly.

17. A method to fabricate a building material, the method comprising:

providing a magnesium oxide (MgO) board;

providing a substrate; and

interposing an adhesive layer between the MgO board and the substrate to laminate the MgO board to the substrate with the adhesive layer to form a laminate.

18. The method of claim 17 wherein the laminate comprises a flame spread rating of about zero according to ASTM E-84.

19. The method of claim 17 wherein the laminate comprises a smoke generation rating of about zero according to ASTM E-84.

20. The method of claim 17 wherein the laminate is noncombustible according to ASTM E-136.

21. The method of claim 17 further comprising a finishing material directly applied to the laminate without additional fire or moisture protection.

22. The method of claim 17 wherein the substrate comprises an oriented strand board (OSB).

23. The method of claim 22 wherein the laminate comprises at least one of a greater resistance to fungal growth than the OSB, a greater structural strength than the OSB, and a greater resistance to moisture than the OSB.

24. The method of claim 17 wherein the substrate comprises a foam core material.

25. The method of claim 17 wherein the adhesive layer is selected from the group consisting of polyvinyl acetate (PVA), water-based polymeric adhesives, solvent-based adhesives, thermostat adhesives, modified starches, liquid moisture cure adhesives, and polyurethane.

26. The method of claim 17 wherein the substrate comprises a joist including an upper flange, a lower flange, and a web interposed between the upper and the lower flanges.

27. The method of claim 26 wherein the MgO board is laminated to at least one side of the web.

28. The method of claim 26 wherein the MgO board is laminated to both sides of the web.

29. The method of claim 26 wherein the MgO board is laminated to the upper flange and the lower flange along the length of the joist.

30. The method of claim 26 wherein the MgO board encases the joist.