US2007261329A1PendingUtilityA1

Inorganic Composite Building Panel

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Assignee: RIGSBY JACKPriority: Dec 16, 2005Filed: Dec 15, 2006Published: Nov 15, 2007
Est. expiryDec 16, 2025(expired)· nominal 20-yr term from priority
Inventors:Jack Dewayne Rigsby, IiRichard F. Wehrli
E04C 2/36E04C 2/288E04C 2/06C04B 28/34E04C 2/26B28B 19/0092C04B 28/342E04C 2/284Y10T29/49629
49
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Claims

Abstract

An inorganic composite is formed from a solution of KH 2 PO 4 mixed with H 2 O, which is then mixed with a metal oxide and a filler material. The mixture of the solution with the metal oxide and filler material forms a flowable slurry. Fibers are then introduced into the slurry. The fibers chemically or mechanically bond with the slurry. The slurry is then cured to form a composite with fibers bonded with the inorganic cement matrix.

Claims

exact text as granted — not AI-modified
1 . An integrated inorganic composite building panel comprising: 
 (a) a first exterior member;    (b) a second exterior member; and    (c) a plurality of interior support members;    wherein said first and second exterior members are integrally attached to said plurality of interior support members.    
   
   
       2 . The building panel of  claim 1 , wherein said inorganic composite building panel is integrated by chemical bonding.  
   
   
       3 . The building panel of  claim 1 , wherein said inorganic composite building panel is integrated by mechanically bonding.  
   
   
       4 . The building panel of  claim 1 , wherein said first and second exterior members are bonded to said plurality of interior support members.  
   
   
       5 . The building panel of  claim 4 , wherein said first and second exterior members are chemically bonded to said plurality of interior support members.  
   
   
       6 . The building panel of  claim 4 , wherein said first and second exterior members are mechanically bonded to said plurality of interior support members.  
   
   
       7 . The building panel of  claim 1 , wherein said plurality of interior support members comprise a bonded inorganic composite material.  
   
   
       8 . The building panel of  claim 7 , wherein said inorganic composite material is chemically bonded.  
   
   
       9 . The building panel of  claim 7 , wherein said inorganic composite material is mechanically bonded.  
   
   
       10 . The building panel of  claim 7 , wherein said bonded inorganic composite material comprises cement and a plurality of fibers.  
   
   
       11 . The building panel of  claim 10 , wherein said cement comprises metal oxide and phosphate.  
   
   
       12 . The building panel of  claim 11 , wherein said metal oxide comprises magnesium oxide.  
   
   
       13 . The building panel of  claim 11 , wherein said phosphate comprises potassium phosphate.  
   
   
       14 . The building panel of  claim 10 , wherein said plurality of fibers comprises a fiber mat.  
   
   
       15 . The building panel of  claim 14 , wherein said fiber mat comprises basalt fibers.  
   
   
       16 . The building panel of  claim 1 , wherein said first exterior member comprises a bonded inorganic composite material.  
   
   
       17 . The building panel of  claim 16 , wherein said inorganic composite material is chemically bonded.  
   
   
       18 . The building panel of  claim 16 , wherein said inorganic composite material is mechanically bonded.  
   
   
       19 . The building panel of  claim 16 , wherein said second exterior member comprises a bonded inorganic composite material.  
   
   
       20 . The building panel of  claim 19 , wherein said inorganic composite material is chemically bonded.  
   
   
       21 . The building panel of  claim 20 , wherein said inorganic composite material is mechanically bonded.  
   
   
       22 . The building panel of  claim 1 , further comprising an insulation material disposed between said plurality of interior support members.  
   
   
       23 . The building panel of  claim 22 , wherein said insulation material comprises an insulative gas.  
   
   
       24 . The building panel of  claim 23 , wherein said insulative gas comprises air.  
   
   
       25 . The building panel of  claim 22 , wherein said insulation material is supportive.  
   
   
       26 . The building panel of  claim 25 , wherein said supportive insulation material comprises foam.  
   
   
       27 . The building panel of  claim 25 , wherein said supportive insulation comprises cardboard.  
   
   
       28 . A method for manufacturing an integrally bonded inorganic composite building panel comprising attaching a plurality of interior support members to a first exterior member and a second exterior member.  
   
   
       29 . The method of  claim 28 , wherein said plurality of interior support members are bonded to said first and second exterior members.  
   
   
       30 . The method of  claim 28 , wherein said plurality of interior support members are chemically bonded to said first and second exterior members.  
   
   
       31 . The method of  claim 28 , wherein said plurality of interior support members are mechanically bonded to said first and second exterior members.  
   
   
       32 . The method of  claim 28 , wherein said plurality of interior support members comprise a bonded inorganic composite material.  
   
   
       33 . The method of  claim 32 , wherein said inorganic composite material is chemically bonded.  
   
   
       34 . The method of  claim 32 , wherein said inorganic composite material is mechanically bonded.  
   
   
       35 . The method of  claim 28 , wherein said first exterior member comprises a bonded inorganic composite material.  
   
   
       36 . The method of  claim 35 , wherein said inorganic composite material is chemically bonded.  
   
   
       37 . The method of  claim 35 , wherein said inorganic composite material is mechanically bonded.  
   
   
       38 . The method of  claim 35 , wherein said second exterior member comprises a bonded inorganic composite material.  
   
   
       39 . The method of  claim 38 , wherein said inorganic composite material is chemically bonded.  
   
   
       40 . The method of  claim 38 , wherein said inorganic composite material is mechanically bonded.  
   
   
       41 . The method of  claim 28 , further comprising an insulation material disposed between said plurality of interior support members.  
   
   
       42 . A system for manufacturing an integrally bonded inorganic composite building panel, said system comprising: 
 (a) a first slurry applicator for applying cement to a fiber material to produce a first exterior member, a second exterior member and a plurality of support members; and    (b) an assembly unit for chemically-bonding a plurality of interior support members to said first and second exterior members.    
   
   
       43 . The system of  claim 42 , further comprising a plurality of rollers for impregnating said fiber material with cement to produce said first and second exterior members.  
   
   
       44 . The system of  claim 42 , further comprising a second slurry applicator for applying cement to a first surface of said first exterior member and to a second surface of said second exterior member.  
   
   
       45 . The system of  claim 42 , further comprising a conveyor for transporting said building panel.

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