US4378401A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Manufacture of structural board panels
Assignee: Borfglace Ltd
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Filing: 1980-03-31
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Granted: 1983-03-29
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Expires: 2000-03-31
Abstract
Abstract A method of forming structural board panels from short strands of bagasse or other cellulistic material. The material resinated, compressed and cured to give an open structural block. A mortar screed of portland cement and sand is then applied to penetrate interstices between the strands and is built up with rendering and facing layers of mortar. A reinforcement, such as an open mesh net of resinated nylon strands may be incorporated in the facing layer.
Inventors
- 👤 Charles L. Wright
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 17:00
CPC Classifications
C; C04; C04B; C04B41/00; C04B41/009; B; B27; B27N; B27N7/00; B27N7/005; C04B28/00; C04B28/02; C04B28/04; C04B41/45; C04B41/50; C04B41/5076; C04B41/5079; E; E04; E04C; E04C2/00; E04C2/02; E04C2/10; E04C2/16; E04C2/18; Y; Y02; Y02W; Y02W30/00; Y02W30/50; Y02W30/91; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249953; Y10T428/249955; Y10T428/249959; Y10T428/249987; Y10T428/24999; Y10T428/25; Y10T428/253; Y10T428/26; Y10T428/263; Y10T442/00; Y10T442/10; Y10T442/102; Y10T442/159; Y10T442/171
Claims Analysis
Total Claims: 22
Claim 1
Independent Claim
86 words
A method of forming a structural board panel including providing a loose mat of overlapping strands of cellulistic material to which a resin adhesive has been applied, compressing and curing said mat to give an open structural block, applying a portland cement mix to penetrate into interstices between said strands, providing a rendering layer on said block, and introducing into a portion of said portland cement mix a reinforcement of resinated filamentary material which is applied as a layer spaced from said block of cellulistic material.
Claim 2
Independent Claim
86 words
A method of forming a structural board panel including providing a loose mat of overlapping strands of cellulistic material to which a resin adhesive has been applied, compressing and curing said mat to give an open structural block, applying a portland cement mix to penetrate into interstices between said strands, providing a rendering layer on said block, and introducing into a portion of said portland cement mix a reinforcement of resinated filamentary material which is applied as a layer spaced from said block of cellulistic material.
Claim 3
Dependent Claim
28 words
A method of forming a structural board panel as claimed in claim 1, wherein a facing layer of said portland cement mix is applied over said rendering layer.
Claim 4
Dependent Claim
41 words
A method of forming a structural board panel as claimed in claim 2, wherein resin is applied to said filamentary material and cured partially to an extent sufficient to achieve an adhesive bond prior to introduction into said portland cement mix.
Claim 5
Dependent Claim
47 words
A method of forming a structural board panel as claimed in claim 3, wherein said resinated filamentary material is introduced into said portland cement mix at a stage in the curing process at which said exothermic reactions in said resin and the portland cement mix mutually assist.
Claim 6
Dependent Claim
24 words
A method of forming a structural board panel as claimed in claim 4, wherein said filamentary material is in the form of nylon strands.
Claim 7
Dependent Claim
29 words
A method of forming a structural board panel as claimed in claim 5 wherein said nylon strands are introduced as an open mesh net into said portland cement mix.
Claim 8
Dependent Claim
34 words
A method of forming a structural board panel as claimed in claim 6, wherein said nylon strands are coated with a water soluble, phenol free, resorcinol formaldehyde novalac resin cross-linked with formaldehyde or paraform.
Claim 9
Dependent Claim
29 words
A method of forming a structural board panel as claimed in claim 7, wherein said nylon strands are introduced as an open mesh net into said portland cement mix.
Claim 10
Independent Claim
158 words
A method of forming a structural board panel including providing a loose mat of overlapping strands of cellulistic material to which a resin adhesive has been applied, compressing and curing said mat to give an open structured block having a density of between 160 and 400 kg/m 3 and surface aperture of between 25% and 75%, applying a portland cement mix to one face of said block to penetrate interstices between said strands to a depth of between 5 and 25 mm, applying a portland cement mix rendering layer onto said face to a thickness of between 3 and 15 mm, laying an open mesh net of nylon strands coated with a water soluble, phenol free, resorcinol formaldehyde novalac resin cross-linked with formaldehyde or paraform and partially cured onto said rendering layer and then applying a portland cement mix facing layer over said open mesh net of nylon strands to a thickness of between 3 and 15 mm.
Claim 11
Independent Claim
158 words
A method of forming a structural board panel including providing a loose mat of overlapping strands of cellulistic material to which a resin adhesive has been applied, compressing and curing said mat to give an open structured block having a density of between 160 and 400 kg/m 3 and surface aperture of between 25% and 75%, applying a portland cement mix to one face of said block to penetrate interstices between said strands to a depth of between 5 and 25 mm, applying a portland cement mix rendering layer onto said face to a thickness of between 3 and 15 mm, laying an open mesh net of nylon strands coated with a water soluble, phenol free, resorcinol formaldehyde novalac resin cross-linked with formaldehyde or paraform and partially cured onto said rendering layer and then applying a portland cement mix facing layer over said open mesh net of nylon strands to a thickness of between 3 and 15 mm.
Claim 12
Dependent Claim
89 words
A structural board panel formed by a method which includes providing a loose mat of overlapping strands of cellulistic material to which a resin adhesive has been applied, compressing and curing said mat to give an open structured block, applying a portland cement mix to penetrate into interstices between said strands and to provide a rendering layer on said block wherein a reinforcement of resinated filamentary material is introduced into a portion of said portland cement mix and applied as a layer spaced from said block of cellulistic material.
Claim 13
Dependent Claim
89 words
A structural board panel formed by a method which includes providing a loose mat of overlapping strands of cellulistic material to which a resin adhesive has been applied, compressing and curing said mat to give an open structured block, applying a portland cement mix to penetrate into interstices between said strands and to provide a rendering layer on said block wherein a reinforcement of resinated filamentary material is introduced into a portion of said portland cement mix and applied as a layer spaced from said block of cellulistic material.
Claim 14
Dependent Claim
24 words
A structural board panel as claimed in claim 10, wherein a facing layer of said portland cement mix is applied over said rendering layer.
Claim 15
Dependent Claim
37 words
A structural board panel as claimed in claim 11, wherein resin is applied to said filamentary material and cured partially to an extent sufficient to achieve an adhesive bond prior to introduction into said portland cement mix.
Claim 16
Dependent Claim
43 words
A structural board panel as claimed in claim 17, wherein said resinated filamentary material is introduced into said portland cement mix at a stage in the curing process at which the exothermic reactions in said resin and said portland cement mix mutually assist.
Claim 17
Dependent Claim
20 words
A structural board panel as claimed in claim 13, wherein said filamentary material is in the form of nylon strands.
Claim 18
Dependent Claim
25 words
A structural board panel as claimed in claim 14 wherein said nylon strands are introduced as an open mesh net into said portland cement mix.
Claim 19
Dependent Claim
30 words
A structural board panel as claimed in claim 15, wherein said nylon strands are coated with a water soluble, phenol free, resorcinol formaldehyde novalac resin cross-linked with formaldehyde or paraform.
Claim 20
Dependent Claim
25 words
A structural board panel as claimed in claim 16, wherein said nylon strands are introduced as an open mesh net into said portland cement mix.
Claim 21
Dependent Claim
158 words
A structural board panel formed by a method including depositing a loose mat of overlapping strands of cellulistic material to which a resin adhesive has been applied, compressing and curing said mat to give an open structured block having a density of between 160 and 400 kg/m 3 and surface aperture of between 25% and 75%, applying a portland cement mix to one face of said block to penetrate interstices between the strands to a depth of between 5 and 25 mm, applying a portland cement mix rendering layer onto said face to a thickness of between 3 and 15 mm, laying an open mesh net of nylon strands coated with a water soluble, phenol free, resorcinol formaldehyde novalac resin cross-linked with formaldehyde or paraform and partially cured onto the rendering layer and then applying a portland cement mix facing layer over said open mesh net of nylon strands to a thickness of between 3 and 15 mm.
Claim 22
Dependent Claim
158 words
A structural board panel formed by a method including depositing a loose mat of overlapping strands of cellulistic material to which a resin adhesive has been applied, compressing and curing said mat to give an open structured block having a density of between 160 and 400 kg/m 3 and surface aperture of between 25% and 75%, applying a portland cement mix to one face of said block to penetrate interstices between the strands to a depth of between 5 and 25 mm, applying a portland cement mix rendering layer onto said face to a thickness of between 3 and 15 mm, laying an open mesh net of nylon strands coated with a water soluble, phenol free, resorcinol formaldehyde novalac resin cross-linked with formaldehyde or paraform and partially cured onto the rendering layer and then applying a portland cement mix facing layer over said open mesh net of nylon strands to a thickness of between 3 and 15 mm.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1986-03-28 | 1986-09-27 | 1987-03-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1990-03-28 | 1990-09-27 | 1991-03-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1994-03-28 | 1994-09-27 | 1995-03-29 | $7700.00 | Window Closed / Lapsed |