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US 10,910,988 B2Granted
Method to make ultra stable structural laminate
AssigneeMitek Holdings, Inc.
InventorsJames A. Wambaugh, Brett Rochner, Cole J. Weinberger
Life of this patent
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Abstract
A method to make an ultra-stable structural laminate of a cementitious material with a nano-molecular veneer and a foam component catalytically reacted into an expanded closed cell foam having a thickness from ⅛th inch to 8 inches, a density from 1.5 pounds/cubic foot to 3 pounds/cubic foot that inter-engages the cementitious material forming a matrix creating the ultra-stable structural laminate with fire resistance; a lateral nail pull strength from 44 pounds to 300 pounds of force; an insulation R value from 1 to 40; a resistance to seismic impact for earthquakes over 3.1 on the Richter Scale; a break point from 7 lbs/inch to 100 lbs/inch; and a resistance to wind shear equivalent to a 15 mph downburst.
Claims21
A method to make a structural laminate, the method comprising:
- (i) forming a cementitious material by combining:
- (a) 29 wt % to 40 wt %, based on the final total weight of the cementitious material, of a magnesium oxide dry powder containing 80 wt % to 98 wt % of magnesium oxide, the magnesium oxide having a surface area ranging from 5 meters2/gram to 50 meters2/gram and an average particle size of from about 0.3 to about 90 microns, and wherein more than about 90% by weight of the magnesium oxide particles have a particle size of less than or equal to about 40 microns;
- (b) 14 wt % to 18 wt %, based on the final total weight of the cementitious material, of magnesium chloride dissolved in water;
- (c) 0.1 wt % to 10 wt %, based on the final total weight of the cementitious material, of a stabilizing material, the stabilizing material comprising:
- a. an aqueous solution comprising 55 wt % to 65 wt % of phosphorous acid (H3PO3);
- or
- b. an aqueous solution comprising 80 wt % to 90 wt % of phosphoric acid (H3PO4);
- thereby forming an amorphous phase cementitious material comprising a plurality of crystals, each of the plurality of crystals having a molecular weight within the range of 280 to 709, and being encapsulated by the amorphous phase cementitious material,
- wherein a majority of the stabilizing material is consumed during curing into a nano-molecular veneer while increasing surface area of the plurality of crystals by 2% to 49%, and
- wherein the nano-molecular veneer is insoluble in water and protects the plurality of crystals from degradation in water at temperatures from 20 degrees to 60 degrees Celsius for from 24 hours to 56 days;
- (ii) catalytically reacting a foam component into an expanded closed cell foam having a thickness from ⅛th inch to 8 inches, and a density from 1.5 pounds/cubic foot to 3 pounds/cubic foot;
- and
- (iii) disposing the cementitious material over the expanded closed cell foam while the closed cell foam is expanding, thereby forming a structural laminate.
10 more elements
A method to make a structural laminate, the method comprising:
- forming a cementitious material by combining:
- (a) 29 wt % to 40 wt %, based on the final total weight of the cementitious material, of a magnesium oxide dry powder containing 80 wt % to 98 wt % of magnesium oxide, the magnesium oxide having a surface area ranging from 5 meters2/gram to 50 meters2/gram and an average particle size of from about 0.3 to about 90 microns, and wherein more than about 90% by weight of the magnesium oxide particles have a particle size of less than or equal to about 40 microns;
- (b) 14 wt % to 18 wt %, based on the final total weight of the cementitious material, of a magnesium chloride dissolved in water;
- (c) 0.1 wt % to 10 wt %, based on the final total weight of the cementitious material, of a stabilizing material, the stabilizing material comprising:
- a. an aqueous solution comprising 55 wt % to 65 wt % of phosphorous acid (H3PO3);
- or
- b. an aqueous solution comprising 80 wt % to 90 wt % of phosphoric acid (H3PO4);
- thereby forming an amorphous phase cementitious material comprising a plurality of crystals, each of the plurality of crystals having a molecular weight within the range of 280 to 709, and being encapsulated by the amorphous phase cementitious material,
- (ii) pouring the cementitious material onto a mold and curing the cementitious material, wherein a majority of the stabilizing material is consumed during curing into a nano-molecular veneer while increasing surface area of the plurality of crystals by 2% to 49%, and the nano-molecular veneer is insoluble in water and protects the plurality of crystals from degradation in water at temperatures from 20 degrees to 60 degrees Celsius for from 24 hours to 56 days;
- (iii) catalytically reacting a foam component into an expanded closed cell foam having a thickness from ⅛th inch to 8 inches, and a density from 1.5 pounds/cubic foot to 3 pounds/cubic foot;
- (iv) disposing the expanded closed cell foam over the cured cementitious material, thereby forming a structural laminate.
8 more elements
Dependencies are inferred from the claim text.