Formulations/Mixtures and improved processes for manufacturing Fire Liner Panels

Abstract

The invention is the development of new and unique formulations and mixtures along with unique and improved manufacturing processes for a clear departure for all manufacturing processes in which calcium silicate or cement-based formulations and mixtures are commonly utilized in manufacturing fire liner panel systems of the prior art. The invention serves the current fire protection/training industry with new and unique formulations and mixtures along with improved manufacturing processes that produce a fire liner panels system with enhanced performance characteristics which are unparalleled teachings not present, nor found in any of the prior art.

Claims

1. A variety of new and unique formulations and mixtures of the invention developed to be enhanced formulations and mixtures as radical replacement for all manufacturing processes in which calcium silicate or cement-based formulations and mixtures that are utilized in the manufacturing of fire liner panel systems of the prior art.

2. The new and unique formulations and mixtures as defined in claim 1 wherein said formulations and mixtures of the invention DO NOT utilize any sand, gravel or steel reinforcement of the prior art as ingredients in formulating the new and unique formulations and mixtures of the invention.

3. The new and unique formulations and mixtures as defined in claim 1 wherein said formulations and mixtures of the invention are augmented with unusually high levels of fly ash, which are teachings not present, nor found in any of the prior art.

4. The new and unique formulations and mixtures as defined in claim 1 wherein said formulations and mixtures of the invention are taught to be exclusively reinforced with glass fiber and glass reinforced woven mesh, which are teachings not present, nor found in any of the prior art.

5. Unique and improved manufacturing processes of the invention developed to be enhanced replacement for all manufacturing processes in which calcium silicate or cement-based formulations and mixtures that are utilized in the manufacturing of fire liner panel systems of the prior art, which are teachings not present, nor found in any of the prior art.

6. The unique and improved manufacturing processes as defined in claim 5 wherein said manufacturing processes of the invention teaches utilizing high temperature water to manufacture the new and unique formulations/mixtures, which are teachings not present, nor found in any of the prior art.

7. The unique and improved manufacturing processes as defined in claim 5 wherein said manufacturing processes of the invention teaches utilizing insulated vacuum molds to retain the high temperature releases generated in the curing process, which are teachings not present, nor found in any of the prior art.

8. The unique and improved manufacturing processes as defined in claim 5 wherein said manufacturing processes of the invention teaches utilizing a custom casting process, which saves on labor and material cost and is not offered by any of the fire liner panel system of the prior art.

9. The unique and improved manufacturing processes as defined in claim 5 wherein said manufacturing processes of the invention teaches utilizing manufacturing process that have created and incorporated a high-temperature casting method which yields increased structural strengths for the fire liner panel that exceeds standard industry practices taught by the prior art and the generation of the high temperature requires no cost for the energy to produce the heat needed for the high temperature effect.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0050] FIG. 1 is a drawing of a perspective view of the base ingredients of the formulations and mixtures of the invention.

[0051] FIG. 2 is a drawing of a side view of a casting of the formulations and mixtures of the invention.

[0052] FIG. 3 is a photo of glass fiber.

[0053] FIG. 4 is a photo of glass reinforced woven.

[0054] FIG. 5 is a photo of the blended cement and fly ash mixture.

[0055] FIG. 6 is a drawing of a side view of a typical mold of the prior art

[0056] FIG. 7 is a drawing of a side view of an improved mold of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0057] New and Unique High Temperature Resistant Cement-Based Formulations/Mixtures of the Invention

[0058] The invention teaches four ingredients are needed for the formulations/mixtures for manufacturing the fire liner panels: FIG. 1 is a drawing of a perspective view of the four base ingredients of the formulations and mixtures of the invention. [0059] 2Fly Ash [0060] 4Portland Cement [0061] 6Glass Fiber [0062] 8Glass Reinforced Woven Mesh

[0063] FIG. 2 is a drawing of a side view of a casting of the formulations and mixtures of the invention. The fly ash 2, Portland cement 4 and glass fiber 6 are mixed together 10 and are reinforced with two layers of the glass reinforced woven mesh 8A/8B as a panel is casted.

[0064] FIG. 3 is a photo of glass fiber.

[0065] FIG. 4 is a photo of glass reinforced woven.

[0066] FIG. 5 is a photo of the blended cement and fly ash mixture.

[0067] Cement/ash Paste/binding agent: The use of Portland Cement/Fly Ash paste as the binding agent/element of the formulations/mixtures in the invention is desirable, preferred, stable and is an unequalled binding agent in terms of being economical, widely available and durable for centuries. This cement/ash paste/binding agent is by itself has a very dense, low/negligible porosity and does not dissolve, emulsify or transform from one state to another once the process of hydration sets the paste into a hardened crystallized state. The invention teaches that the Portland cement be highly augmented with fly ash to radically improve performance characteristics and increased fire/heat resistance of the base paste/binder.

[0068] Fly AshThe fly ash used in the formulations/mixtures of the invention ultimately provide vast diversity and agility of application uses and allows specific and targeted performance characteristics to be yielded The invention teaches the use of two types of fly ash: [0069] Class F [0070] Class C

[0071] There are various types of cements that can be used in the various and different formulations/mixtures of the invention. The different types of cements that can be. The various types of cement to be used are substantiated below, as per ASTM C150: [0072] Type IHigh Early Strength [0073] Type IIModerate specified in said formulations/mixtures ultimately provide vast diversity and agility of application uses and allows specific and targeted performance characteristics to be yielded Sulfate Resistance [0074] Type II (MH)Moderate Heat of Hydration [0075] Type IIIHigh Early Strength [0076] Type IVLow Heat Hydration [0077] Type VHigh Sulfate Resistance

[0078] In addition blended hydraulic type cements to be inclusive as cements for use in formulation/mixtures of the invention, as per ASTM C595: [0079] Type ILPortland-Limestone Cement [0080] Type ISPortland-Slag Cement [0081] Type IPPortland-Pozzonlan Cement [0082] Type ITTernary Blended Cement

[0083] The blend ratios for the Portland cement to the fly ash can be adjusted to meet specific and targeted performance characteristics. See the cement/ash batching weight ratios below:

TABLE-US-00001 Portland Cement Fly Ash Ratio % 75 lbs 50 lbs 60/40 68.75 lbs 56.25 lbs 55/45 62.5 lbs 62.5 lbs 50/50 56.25 lbs 68.75 lbs 45/55 50 lbs 75 lbs 40/60

[0084] Glass Fiber ReinforcementGlass is utilized as much improved aggregate. There are different available types and sizes of glass fiber. The invention teaches a variety of blended fiber ratios which can be adjusted to meet specific and targeted performance characteristics. The amount of fiber needed for a batch of cement/ash from abovesee the fiber batch weights below:

TABLE-US-00002 % of Type-A % of Type-B % of Type-C Total-Lbs 20% 30% 50% 7 Lbs 21% 35% 44% 8 Lbs 22% 37% 40% 9 Lbs 25% 40% 35% 10 Lbs

[0085] Glass Reinforced Woven MeshThe invention teaches the utilization of glass reinforced woven mesh to further reinforce the formulations/mixtures for manufacturing the fire liner panels of the invention. The invention teaches the placement of two layers of the glass reinforced woven mesh in each fire liner panel casting. There are two main reasons for two layers of the mesh: [0086] 1. Each of the panels of the invention are 1.77 square feet with the span between the structural channels that the panels are mounted on is no more that 12 inches apart. [0087] 2. The panels of the invention are cast at one inch thickness.

[0088] With the installation criteria being as described as above two layers of the glass reinforced woven mesh is more than sufficient structural reinforcement to meet any and all structural requirement of the NFPA building code requirements. If larger sized panels and or panels that can serve longer spans the invention provides for modifications to formulations/mixtures with more fiber and mesh reinforcements along with allowances for increased panel profile designs.

[0089] The invention teaches adjustable formulations in batching the four ingredients for casting fire liner panels to provide agility in performance characteristic yields. The key to the successes of the invention is there's absolutely NO use of sand, gravel or steel reinforcements taught by the invention. Instead the invention exclusively teaches the use of fly ash, glass fiber and glass reinforcement woven mesh.

[0090] Unique and Improved Manufacturing Processes Taught by the Invention

[0091] The invention uniquely teaches the observation and practice of controlling ambient temperature ranges of between 70 F.-90 F. prior to casting, during casting, and post temperatures during curing of the formulations/mixtures as an intangible conditioning of the unique and improved manufacturing processes of the invention.

[0092] The invention teaches the elements/compounds/ingredients of the invention formulas are stored to the same temperatures. The molds used in the castings are stored and used in the same temperature ranges.

[0093] The invention further teaches the utilization of insulated vacuum molds which provide efficiencies and effectiveness in the retention of the high temperature releases generated by the inventions formulations and mixtures in the curing phases. In the curing phase where both the chemical reaction of the cement/pozzolans/water and from the heat that is caused mechanically by the friction of water molecules that hydration produce.

[0094] The initial hot water temperatures of 105 F. coupled with the increased temperatures generated during curing along with the retention of these temperatures act like a catalyst for high temperature accelerant in the curing of the castings. The invention teaches a methodology of a free high heat baking process with zero energy costs.

[0095] The invention teaches a moisture process with the deployment of the anti-hydration membrane which produces a beneficial effect of retaining the moisture of the water molecules that normally leave the mold/casting in the hydration/curing phase of the prior art. The invention teaches an improved and more ideal curing condition in that the formulations/mixtures cure faster and harder due to the retention of increased moist environment over the drier environments taught in the prior art.

[0096] These practices are proven to lead to castings with earlier and higher strengths, and the enhanced performance characteristics of comprehensive, flexural (tensile bending), shear, torsion and durability with less porosity, when compared to castings that were produced using cold water or un-improved molds.

[0097] FIG. 6 is a side view of a typical mold of the prior art, which consist of just two elements the hard mold 12 and rubber mold 14 that produces the casting 16. The prior art doesn't teaches the three improvements of the invention. (1)The use of insulated mold with insulated top. (2)The use of anti-hydration membrane. (3)The use of vacuum molding technologies.

[0098] FIG. 7 is a side view of an improved mold of the invention. The improvements taught by the invention are first the insulated 18B hard mold 20, which holds the rubber mold 14 and provide the profile imaging tooling to produce the casting 16. The next improvement is the utilization of the anti-hydration rubber membrane 24, which performs two actions (a) It retains the moisture that normally escapes from the casting/mold during the cure phase. (b) It acts as a gasket between the insulated 18B hard mold 20 and the insulated 18A top 22. The anti-hydration rubber membrane 24 is laid down over the casting 16 once it is completed being casted. The insulated 18A top 22 is bolted 28A/28B down on the insulated 18B hard mold 20 then a vacuum is attached to the vacuum valve 26 and the vacuum is applied to the mold and left to cure over night.