Unique Formulations/Mixtures and Unique and Improved Processes for Manufacturing Structural Insulated Panels Systems (SIPS)

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 cement-based formulations and mixtures are commonly utilized in manufacturing SIPS of the prior art and or the teachings of the poured/casted/formed cement based formulations/mixtures and manufacturing processes of the prior art of building/construction industry. The invention serves the current building/construction industry with new and unique formulations and mixtures along with unique and improved manufacturing processes that produce SIPS 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 cement-based formulations and mixtures that are utilized in the manufacturing of SIPS of the prior art and or the teachings of the poured/casted/formed cement based formulations/mixtures and manufacturing processes of the prior art of building/construction industry.

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, which are teachings not present, nor found in any of the prior art.

3. 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.

4. The new and unique formulations and mixtures as defined in claim 1 wherein said formulations and mixtures of the invention produce a water tight integrity in the structural facing, which prevent water intrusion and doesn't require the installation of a vapor/moisture barrier.

5. The new and unique formulations and mixtures as defined in claim 1 wherein said formulations and mixtures of the invention produce SIPS that is bug, insect, termite-pest/vermin-rodent proof, which are teachings not present, nor found in any of the prior art.

6. The new and unique formulations and mixtures as defined in claim 1 wherein said formulations and mixtures of the invention produce SIPS that is fire proof and does not burn, which are teachings not present, nor found in any of the prior art.

7. The new and unique formulations and mixtures as defined in claim 1 wherein said formulations and mixtures of the invention produce SIPS that does not rot, decay, warp or split and provides excellent mold/mildew resistant, which are teachings not present, nor found in any of the prior art.

8. Unique and improved manufacturing processes of the invention developed to be enhanced augmentation/replacement for all manufacturing processes in which cement-based formulations and mixtures that are utilized in the manufacturing processes of the prior art, which are teachings not present, nor found in any of the prior art.

9. The unique and improved manufacturing processes as defined in claim 4 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.

10. The unique and improved manufacturing processes as defined in claim 4 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.

11. The unique and improved manufacturing processes as defined in claim 4 wherein said manufacturing processes of the invention teaches utilizing a new and unique high temp moist curing process, which is achieved with the deployment of the anti-hydration membrane which is placed under applied vacuum, which are teachings not present, nor found in any of the prior art.

12. The unique and improved manufacturing processes as defined in claim 4 wherein said manufacturing processes of the invention teaches utilizing a custom casting process, which save labor and material cost and is not taught by any of the prior art.

13. The unique and improved manufacturing processes as defined in claim 4 wherein said manufacturing processes of the invention teaches utilizing manufacturing process that have created and incorporated a high-temperature casting/curing process that utilize unique and improved insulated vacuum molds which are not practices taught by the prior art.

14. The unique and improved manufacturing processes as defined in claim 8 wherein said manufacturing processes of the invention teaches utilizing manufacturing process that have created and incorporated high-temperature casting/curing methods in which the generation of the high temperature cast/cure effect requires no expenditure of cost for the energy to produce and retain the heat needed for the high temperature casting/curing process.

15. The unique and improved manufacturing processes as defined in claim 4 wherein said manufacturing processes of the invention teaches that the cement based structural facing for the interior of the SIP panel may be put into service without an interior coating, sheeting, or paneling materials .etc. being purchased or installed by unique and improved manufacturing processes, which produce a wide range of integrated molded textures such as stucco/plaster, drywall textures, wood paneling, stone, and brick .etc., which are achieved in the manufacturing processes.

16. The unique and improved manufacturing processes as defined in claim 4 wherein said manufacturing processes of the invention teaches that the cement based structural facing for the exterior of the SIP panel may be put into service without an exterior coating, sheeting, or siding materials .etc. being purchased or installed by unique and improved manufacturing processes, which produce a wide range of integrated molded textures such as stucco/plaster, lapped siding, stone, and brick .etc., which are achieved in the manufacturing processes.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0046] FIG. 1 is a drawing of a perspective view of the base ingredients of the new and unique formulations and mixtures of the invention.

[0047] FIG. 2 is a drawing of a side view of a Structural Insulated Panel casted with the new and unique formulations and mixtures of the invention.

[0048] FIG. 3 is a photo of glass fiber.

[0049] FIG. 4 is a photo of glass reinforced woven.

[0050] FIG. 5 is a photo of the Portland cement.

[0051] FIG. 6 is a drawing of a side view of a typical mold and casting of the prior art

[0052] FIG. 7 is a drawing of a side view of an improved insulated vacuum mold and casting of the invention.

DETAILED DESCRIPTION OF THE INVENTION

New and Unique Cement-Based Formulations/Mixtures of the Invention

[0053] The invention teaches three ingredients are needed for the new and unique formulations/mixtures for manufacturing the SIPS: FIG. 1 is a drawing of a perspective view of the three base ingredients of the new and unique formulations and mixtures of the invention. [0054] 2Portland Cement [0055] 4Glass Fiber [0056] 6Glass Reinforced Woven Mesh

[0057] FIG. 2 is a drawing of a side view of a Structural Insulated Panel casted with the new and unique formulations and mixtures of the invention. The Portland cement 2 and glass fiber 4 are mixed together 8 and are reinforced with two layers of the glass reinforced woven mesh 6A/6B as each structural facing is casted. The Spray Polyurethane Foam (SPF) core 10 which bonds the two cement-based structural facings SF1 together and adds to the structural strength of the SIPS of the invention.

[0058] FIG. 3 is a photo of glass fiber.

[0059] FIG. 4 is a photo of glass reinforced woven.

[0060] FIG. 5 is a photo of the Portland cement.

[0061] Cement/ash Paste/binding agent: The use of Portland cement paste as the binding agent/element of the new and unique 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 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 typical batch size taught by the invention requires 125 lbs of Portland cement to make the cement paste for a batch of a mixture for casting.

[0062] There are various types of cements that can be used in the various and different new and unique formulations/mixtures of the invention. The various types of cement to be used are substantiated below, as per ASTM C150: [0063] Type IHigh Early Strength [0064] 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 [0065] Type II (MH)Moderate Heat of Hydration [0066] Type IIIHigh Early Strength [0067] Type IVLow Heat Hydration [0068] Type VHigh Sulfate Resistance [0069] In addition, blended hydraulic type cements to be inclusive as cements for use in formulation/mixtures of the invention, as per ASTM C595: [0070] Type ILPortlandLimestone Cement [0071] Type ISPortlandSlag Cement [0072] Type IPPortlandPozzolan Cement [0073] Type ITTernary Blended Cement

[0074] Glass Fiber ReinforcementGlass is utilized as a much improved and stable aggregate for the new and unique formulations/mixtures of the invention. There are different types and sizes of glass fiber available for agility with formula diversity in servicing different applications. The invention teaches a variety of ratios for the blending of fiber which can be adjusted to meet specific and targeted performance characteristics. The amount of fiber needed for a batch of cement paste from abovesee the fiber batch weights below:

TABLE-US-00001 % 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

[0075] Glass Reinforced Woven MeshThe invention teaches the utilization of glass reinforced woven mesh to further reinforce the new and unique formulations/mixtures for manufacturing the SIPS of the invention. The invention teaches the placement of two layers of the glass reinforced woven mesh in each of the two cement-based structural facing castings. The invention teaches the use of more layers of the glass reinforced woven mesh to further reinforce the new and unique formulations/mixtures for larger SIP panels capable of increase load bearing characteristics as may be required in serving varied applications.

[0076] The invention teaches adjustable formulations in batching the three ingredients for casting SIPS of the invention 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 cement paste, glass fiber and glass reinforcement woven mesh in producing the new and unique formulations/mixtures of the invention.

Unique and Improved Manufacturing Processes Taught by the Invention

[0077] The invention uniquely teaches the observation and practice of controlling ambient temperature of the production environment of the manufacturing with ranges of between 70 F.-90 F. prior to casting, during casting, and post temperatures during curing of the new and unique formulations/mixtures as an intangible conditioning of the unique and improved manufacturing processes of the invention.

[0078] The invention further teaches the elements/compounds/ingredients of the invention formulas are stored at the same temperature ranges. The insulated vacuum molds and all the production tools and equipment used in all the production phases are also stored and utilized at the same increased temperature ranges.

[0079] The invention teaches the utilization of insulated vacuum molds which provide efficiencies and effectiveness in the retention of the high temperature releases generated by the inventions new and unique 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.

[0080] The initial hot water temperatures of 105 F. coupled with the increased temperatures generated during curing along with the insulated vacuum molds that facilitate the retention of these temperatures act like a catalyst in the development of a high temperature accelerated curing of the castings. The invention teaches a methodology of a free high heat baking process with zero energy costs. In this teaching of the invention superior and dramatically increased performance characteristics are yielded. These processes are not taught nor found in the prior art of SIPS and or the teachings of the poured/casted/formed cement based formulations/mixtures and manufacturing processes of the prior art of building/construction industry as a whole

[0081] The invention teaches a new and unique high temp moist curing process, which is achieved with the deployment of the anti-hydration membrane which under applied vacuum coupled with high temperature produces a beneficial effect of retaining the moisture of the water molecules that normally leave the open un-insulated mold/casting in the hydration/curing phase of the prior art. The invention teaches an improved and more ideal curing conditioning in that the casted formulations/mixtures cure faster and harder due to the retention of an increased moist curing environment over the drier curing environmental conditions taught in the prior art.

[0082] 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, un-improved molds i.e. the manufacturing processes of the prior art.

[0083] 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 teach the three improvements of the invention. (1)The use of insulated vacuum mold with insulated top. (2)The use of anti-hydration membrane. (3)The use of vacuum molding technologies.

[0084] FIG. 7 is a side view of an improved insulated vacuum 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 provides the profile imaging tooling to produce the designed 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 the heated moist curing process over night.