Patent JPS5082041A successfully refreshed from Google Patents.
US5600930A
Expired / Lapsed
US
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Construction system using lightweight fire-resistant panels
Assignee: Individual
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Filing: 1996-02-29
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Granted: 1997-02-11
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Expires: 2016-02-29
Abstract
Abstract A fire-resistant construction system is described comprising lightweight rigid panels forming structural walls, ceilings or partitions and connector members for joining the rigid panels to form a structure. Each rigid panel has substantial length and width relative to thickness and is formed of small ceramic or glass hollow microspheres having particle sizes of less than about 2 mm and a density of less than about 0.75 g/cc. These small microspheres are bonded together to form a rigid panel by means of a settleable binder material, and each panel also has a plurality of equally spaces holes formed therein and extending the full length of the panel. Each connector member comprises an L-shaped member with each arm of the L-shaped member having tubular sleeves extending perpendicularly therefrom and being adapted to fit snugly within the holes of the rigid panels.
Inventors
- 👤 Ernest R. Drucker
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 10:50
CPC Classifications
E; E04; E04B; E04B2/00; E04B2/74; E04B2/7407; E04B2/7409; E04B2/7411; B; B29; B29C; B29C33/00; B29C33/0033; B29C70/00; B29C70/58; B29C70/66; E04B1/00; E04B1/38; E04B1/61; E04B1/6108; E04B1/612; E04B1/6145; E04C; E04C2/00; E04C2/02; E04C2/26; E04C2/284; E04C2/288; B29C33/44; B29C33/48; B29C33/50; B29K; B29K2105/00; B29K2105/06; B29K2105/16; B29K2105/165; B29K2709/00; B29K2709/08; B29L; B29L2031/00; B29L2031/776
Claims Analysis
Total Claims: 34
Claim 1
Independent Claim
141 words
A fire-resistant construction system comprising lightweight rigid panels forming structural walls, ceilings or partitions and connector members for joining the rigid panels to form a structure wherein (a) each rigid panel has substantial length and width relative to thickness and is formed of small ceramic or glass hollow microspheres having particle sizes of less than about 2 mm and a density of less than about 0.75 g/cc, said small microspheres being bonded together to form a rigid panel by means of a settleable binder material, and each panel also having a plurality of equally spaced holes formed therein and extending the full length of the panel, and (b) each connector member comprises an L-shaped member with each arm of said L-shaped member having tubular portions extending perpendicularly therefrom and being adapted to fit snugly within the holes of the rigid panels.
Claim 2
Dependent Claim
141 words
A fire-resistant construction system comprising lightweight rigid panels forming structural walls, ceilings or partitions and connector members for joining the rigid panels to form a structure wherein (a) each rigid panel has substantial length and width relative to thickness and is formed of small ceramic or glass hollow microspheres having particle sizes of less than about 2 mm and a density of less than about 0.75 g/cc, said small microspheres being bonded together to form a rigid panel by means of a settleable binder material, and each panel also having a plurality of equally spaced holes formed therein and extending the full length of the panel, and (b) each connector member comprises an L-shaped member with each arm of said L-shaped member having tubular portions extending perpendicularly therefrom and being adapted to fit snugly within the holes of the rigid panels.
Claim 3
Dependent Claim
18 words
A construction system according to claim 1 wherein the rigid panel has a thickness of about 5-15 cm.
Claim 4
Dependent Claim
16 words
A construction system according to claim 1 wherein the holes in the rigid panels are cylindrical.
Claim 5
Dependent Claim
27 words
A construction system according to claim 3 wherein there is at least 2 cm of rigid panel material between each hole and the face of a panel.
Claim 6
Dependent Claim
29 words
A construction system according to claim 3 wherein the cross-sectional area of the holes in a panel comprise at least 25% of the total cross-sectional area of a panel.
Claim 7
Dependent Claim
23 words
A construction system according to claim 1 wherein the rigid panels have a density of about 10 to 25 pounds per cubic foot.
Claim 8
Dependent Claim
22 words
A construction system according to claim 1 wherein a gypsum wallboard is bonded to at least one face of a rigid panel.
Claim 9
Dependent Claim
22 words
A construction system according to claim 1 wherein a fibreglass sheet is bonded to at least one face of a rigid panel.
Claim 10
Dependent Claim
34 words
A construction system according to claim 3 wherein the settleable binder material comprises a thin coating on the outer surfaces of the microspheres and bonds together contacting microspheres to form a light, rigid structure.
Claim 11
Dependent Claim
17 words
A construction system according to claim 3 wherein the settleable binder material is an organic resin binder.
Claim 12
Dependent Claim
17 words
A construction system according to claim 3 wherein the settleable binder material is a thermosetting resin binder.
Claim 13
Dependent Claim
16 words
A construction system according to claim 3 wherein the settleable binder material is an epoxy adhesive.
Claim 14
Dependent Claim
14 words
A construction system according to claim 10 wherein the resin is a polyester resin.
Claim 15
Dependent Claim
15 words
A construction system according to claim 3 wherein the settleable binder is a urea-based adhesive.
Claim 16
Dependent Claim
35 words
A construction system according to claim 3 wherein the microspheres are glass microspheres having an average particle density in the range of about 0.15-0.6 g/cc and particle diameters in the range of about 10-200 μm.
Claim 17
Dependent Claim
21 words
A construction system according to claim 15 wherein the microspheres have average wall thicknesses in the range of about 0.5-2.0 μm.
Claim 18
Dependent Claim
19 words
A construction system according to claim 16 wherein the microspheres have compressive strengths in the range of 250-10,000 psi.
Claim 19
Dependent Claim
15 words
A construction system according to claim 1 wherein the connector members are formed of plastic.
Claim 20
Dependent Claim
15 words
A construction system according to claim 1 wherein the connector members are formed of fibreglass.
Claim 21
Dependent Claim
15 words
A construction system according to claim 1 wherein the connector members are formed of metal.
Claim 22
Dependent Claim
23 words
A construction system according to claim 1 wherein a rigid panel for use as a ceiling structure contains steel reinforcing bars embedded therein.
Claim 23
Dependent Claim
18 words
A construction system according to claim 21 wherein the reinforcing bars are spaced about 12 to 20 cm.
Claim 24
Dependent Claim
157 words
A process for producing a fire-resistant, composite construction panel having a rigid core formed of bonded together small ceramic or glass hollow microspheres and cladding layers bonded to the opposed faces of said core, comprising the steps of placing a first cladding layer in a press mould, arranging in said mould a series of equally spaced inflated plastic tubes, said tubes forming regular cylinders under inflation and collapsing flat when deflated, dispensing onto said first cladding layer a layer of free flowing small ceramic or glass hollow microspheres, said microspheres being coated with a settable binder material, placing a second cladding layer on top of the layer of coated microspheres, pressing the first and second cladding layers and layer of coated microspheres together and curing the binder material while pressing to form the composite construction panel, and deflating and removing the plastic tubes to form a panel having a series of equally spaced cylindrical holes extending therethrough.
Claim 25
Dependent Claim
157 words
A process for producing a fire-resistant, composite construction panel having a rigid core formed of bonded together small ceramic or glass hollow microspheres and cladding layers bonded to the opposed faces of said core, comprising the steps of placing a first cladding layer in a press mould, arranging in said mould a series of equally spaced inflated plastic tubes, said tubes forming regular cylinders under inflation and collapsing flat when deflated, dispensing onto said first cladding layer a layer of free flowing small ceramic or glass hollow microspheres, said microspheres being coated with a settable binder material, placing a second cladding layer on top of the layer of coated microspheres, pressing the first and second cladding layers and layer of coated microspheres together and curing the binder material while pressing to form the composite construction panel, and deflating and removing the plastic tubes to form a panel having a series of equally spaced cylindrical holes extending therethrough.
Claim 26
Dependent Claim
38 words
A process according to claim 23 wherein said microspheres are dispensed by falling from a dispenser through a spray of settable binder material, whereby the microspheres are coated with binder material before collecting on the first cladding layer.
Claim 27
Dependent Claim
31 words
A process according to claim 23 wherein said microspheres are coated with a settable binder material in a separate operation and said coated microspheres are dispensed by falling from a dispenser.
Claim 28
Dependent Claim
21 words
A process according to claim 23 wherein the composite is compressed under vacuum to form a rigid core of bonded microspheres.
Claim 29
Dependent Claim
15 words
A process according to claim 26 wherein the binder material is a thermosetting resin binder.
Claim 30
Dependent Claim
14 words
A process according to claim 26 wherein the binder material is an epoxy adhesive.
Claim 31
Dependent Claim
13 words
A process according to claim 26 wherein the resin is a polyester resin.
Claim 32
Dependent Claim
14 words
A process according to claim 26 wherein the binder material is a urea-based adhesive.
Claim 33
Dependent Claim
16 words
A process according to claim 23 wherein the microspheres have diameters of less than 2 mm.
Claim 34
Dependent Claim
17 words
A process according to claim 31 wherein the microspheres have a density of less an 0.75 g/cc.
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) | 2000-02-11 | 2000-08-12 | 2001-02-11 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2004-02-11 | 2004-08-12 | 2005-02-11 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2008-02-11 | 2008-08-12 | 2009-02-11 | $7700.00 | Window Closed / Lapsed |