WO2014066857A1

WO2014066857A1 - Building panels

Info

Publication number: WO2014066857A1
Application number: PCT/US2013/066973
Authority: WO
Inventors: Karen M. Slimak
Original assignee: Individual
Current assignee: Individual
Priority date: 2012-10-25
Filing date: 2013-10-25
Publication date: 2014-05-01
Anticipated expiration: 2015-04-25

Abstract

The present invention is directed to building panels comprising a lingo-cellulosic material impregnated with, a soluble alkali metal, silicate which, is polymerized and rendered water insoluble to form a building panel, with edges. At least one of the edges is provided with a joining element selected from the group consisting of a tongue or a groove with an integral locking element. Products manufactured indude floor pane], ceiling panel, wall panel, floor joist, roof joist, roofing panels, sheathing panels, post, railing, decking, wainscoting, fencing, piling, furniture, cabinetry, window frames, I-beam, glue lam structures and fixtures.

Description

BUILDING PANELS

Background of the Invention

Ϊ, Field of the Invention

The present invention is directed to building panels, especially building panels that are formed with joints to join to a similar or dissimilar panel or other pari, in particular, the building panels of the invention are characterized by environmental stability, moisture resistance, electrical insulative properties, and can be used in diverse environments from interior floor, wall and celling panels, exterior applications, such as roofs, sidings and other home building applications, and marine environments, such as floor, wall and ceiling panels of ships.

2. Description of the Related Art

The existence of joints in carpentry is a well known phenomenon as such have been described in detail, in Knight^'s American Mechanical Dictionary, Hurd & ^'Houghton, Cambridge; The Riverside Press, N.Y., 1876, Vol. If pp. .1217-18, incorporated herein by- reference. Such joints commonly use groove and tenon (or tongue) configurations. More recently, the building products industry has manufactured tongue and groove joints with integral locking configurations, important among these configurations can be mentioned United States Patents 6,1.01 ,778; 6,006.486 and 5,706,621 , the entire disclosures of which are herein incorporated by reference.

However, the problem with each of these prior art panels is that they are extremely sensitive to environmental conditions, especially moisture and even humidity. Thus, the use of the panels in the prior art have been limited to interior applications, such as the inieriors of buildings, and even there, have been confined to applications which do not involve high humidity or standing water applications. Thus, these products were not available for use in bathrooms, and certainly could not be used in marine applications, e.g., shipbuilding. A further drawback of the lack of dimensional stability of these prior ait panel is that they cannot be affixed or anchored to a supporting structure, such as a subiloor. Thus, all these prior art panels, when used as flooring are not affixed to the subiloor, and are in fact spaced from exterior walls, so that they "float'^" upon the supporting structure whereby a plurality of assembled floor panels can expand and contract as a unit. Otherwise, the joints between the individual panels will either open, creating not only an unsightly appearance, but also an entry- way for debris and water; or alternatively rise relative to an edge of the adjacent panel to which it is joined, resulting in what is termed in the art as a "proud" edge, "Proud" edges can catch the heel of pedestrian traffic on a floor and can be chipped or broken when furniture or other elements are slid into contact with the "proud' edge. Furthermore, when the edges of prior art panels are milled to form the joints, individual fibers are exposed creating a wicking passageway into the Interior of the panels for moisture. These passageways, when exposed to moisture, wick the moisture into the ulterior of the panels causing expansion, warping, and potentially may ultimately lead to delamkation of the panels.

Furthermore, these panels all include synthetic polymers, such as phenol-formaldehyde, urea-formaldehyde, melamine and similar resins which release volatile organic components ("VOC's") into the environment, not only during their manufacture, but as residues during use, albeit at lower concentrations. Further, upon ignition, as during a fire, these materials release noxious and dangerous gases. A further drawback of the prior art products is that they are not electrically insulating, and in view of their chemical composition, electrical conductors, such as power cables, communication cables and other electrically conductive wiring have not been incorporated directly into the panels themselves.

Thus, there exists a continuing need to provide improved building panels which avoid all these undesirable properties of prior art panels, mid which do not limit the applications for which building panels are required.

Brief Summary of the Invention

In one embodiment of the invention, building panels are made from ligno-cellulose based materials including natural wood, wood fibers, wood particles, wood chips, wood strands, wood slivers, wood veneers, flax, jute, hemp, ramie, kenaf, straw, bagasse, bark, bamboo and similar ligno-cellulose based materials. The foregoing materials, especially when present in particulate form, such as fibers, chips, strands, particles and slivers may also include fillers of non-organic materials or minerals, such as ground marble, mica, stone chips and dust, sand, lime, and other inorganic materials. The latter are particularly desirable when the building panel is used as a core for a decorative surface material, such as a core for a laminate, a wood veneer, a metal cladding, glass, ceramic, fabric, cork, rubber, plastic, such as vinyl, or other decorative surface elements.

In all embodiments of the invention the iigno-eeilu!osic materials, with or without the inorganic fillers, are impregnated (as used in this specification "impregnated" means coated on a surface or coated onto and penetrating into the interior of a three-dimensional object (e.g., wood, fiber, wood chip, wood veneer, etc.)) with an alkali-metal silicate, most preferably a sodium silicate, which has been subsequently thermally treated to polymerize the alkali-metal silicate and transform it into an insoluble form. The thermal treatment may be achieved by convection, radiation or other heat treatment or by action of radiation, most preferably microwave radiation. The resultant ligno-cellulose product is water resistant, posesses dimensional stability under both high humidity and standing water conditions, is an electrical insulator, and can be cut, milled or broached, or otherwise machined into various sized and shaped products.

in some embodiments of the invention, the resultant ligno-cellulose products can be cut and milled, or milled and broached into building panels having at least one, preferably two, and most preferably all edges milled and/or milled and broached to form joining elements of the tongue and groove type with integral locking elements. While the presence of the locking elements obviates the need for an adhesive, it is clearly within the scope of the invention tha the provision of "glue" in the j oint, will not depart from the teachings of the invention. In such circumstances both the provision of "fresh glue", (an adhesive applied at the time of joining the joining elements), or the so called "pre- glue", (a glue applied at the factory during manufacture of the joining elements, and activated at the time of joining by a solvent, such as water or organic solvent), are both contemplated as falling within the term "glue".

Milling or milling and broaching to form the tongue and groove joining portions of the panels is preferably performed after the building panels has been stabilized by the thermal or radiation treatment of the impregnated alkali-metal silicate to render it water insoluble, although it is also possible to machine the panels before the impregnation and ihermai/radiation treatment- process is performed.

in particularly preferred embodiments, the joint elements can include a void in which electrically conductive wires, cables, electrical and optical communication cables, and other electrically conductive elements (hereinafter collectively "electrically conductive wires or cables") can be placed into direct contact with the building panels. The electrically conductive wires can be placed as bare wires or with conventional electrically insulative coverings, such as rubber or synthetic polymers, in the voids. The voids can be milled and/or milled and broached to provide suitable voids of a size, shape and location in the joint to receive the electrically conductive wires or cables. Other techniques of creating and/or shaping the voids may include drilling alone or drilling and broaching, or drilling and drifting. The combination of broaching or drifting in combination with either a drilling or milling step permits the formation of shapes that could not be achieved by drilling or milling alone.

In other embodiments of the invention, the interior of the building panels, at positions removed from the edges, can be milled, as by drilling or boring, or by a combination of milling and broaching and/or drifting to form voids at least partially, and sometimes completely through the building panel, for the purpose of receiving electrically conductive wires and cables. The wires or cables may be housed in the void so as to terminate at a particular location in the panel, such that the wires may be subsequently accessed by cutting into a face of the panel to electricall connect an electrical connection box, access the wires and/or electrically connect an electrical fixture, e.g., light, motor or bell to the electrical wires in the void.

in other embodiments, the building panels may be cut and milled into other shapes, such as a floor panel, a ceiling panel, a wall panel, components of a wail, floor, or ceiling system, a floor, doorway or window moldings, or into parts for furniture, fixtures and other household or commercial objects. The presence of voids either in, or adjacent, the joining parts, or alternately remote from the joining parts, is also contemplated in those embodiments.

The invention also has particular utility in the maritime industry, as parts of ships for interior rooms, galleys, passageways, overheads and decks, where the presence of dimensionally stable building panels in the presense of high humidity conditions, of low or no VOC emissions, water and fire resistant construction and of an electrically insulative nature are particularly desirable. The presence of voids for receiving electrically conductive wires and cables are of particular interest in the shipbuilding environment. Although I have disclosed the invention, primarily in terms of building panels, moldings, furniture and fixtures, the dimensionally stable, electricall insulating properties of the ligno-cellulose products of the invention can also be used for windows, cabinetry, forms for concrete, floor and roof joists, composite I-beams, roofing panels, sheathing, plywood, electrical conduits, housings, including connection boxes, for wiring, siding, posts, particularly lamp posts, railings, deckings, wainscoting, fences, pilings, window and mirror frames, glue lams or Iaminated panels formed of individually stacked panels Iaminated together of any width, any length, any thickness and stable in all dimensions and other building structures where both dimensionally stable properties in the presence of high humidity or weather exposure conditions and electrically insulative properties, especially containing voids for receiving electrically conductive wires and cables is desirable. Panels made according to the invention are not limited to joints made only on narrow edges, but can have the joint on the wide surface instead of, or in addition to joints on the narrow edges.

These and other embodiments of the invention will be further described in connection with the appended drawings and description of the preferred embodiments.

Brief Description of the Drawings

Fig. 1 is a schematic representation of a first embodiment of a pair of assembled panels according to the invention;

Fig. 2 is a schematic representation of a second embodiment of a pair of assembled panels according to the invention;

Fig, 3 is a schematic representation of a third embodiment of a pair of assembled panels according to the invention;

Fig. 4 is a schematic representation of a fourth embodiment of a pair of assembled panels according to the invention;

Fig. 5a is a schematic representation of a fifth embodiment of a left hand panel according to the invention;

Fig. 5b is a schematic representation of a fifth embodiment of a right hand panel to be joi ned to the panel of Fig 5a according to the invention;

Fig. 6a is a schematic representation of a sixth embodiment of a left hand panel according to the invention;

Fig. 6b is a schematic representation of a sixth embodiment of a right hand panel to be joined to the panel of Fig 6a according to the invention;

Fig, 7 is a schematic representation of a seventh embodiment of a panel according to the invention; Fig 8 is a schematic representation of an I-beam according to the invention;

Fig 9 is a schematic representation of a roofing system according to the invention;

Fig 10 is a schematic representation of an assembly of building panels according to a further embodiment of the Invention;

Fig 11 is a schematic representation of cabinet with a glass face which are attached with interlocking frame inside corners;

Fig 12 is a schematic representation of a window attached with interlocking frame inside corners;

Fig 13 is a schematic representation of a portion of the frame suitable for use in forming the articles of Fig 1 1 and Fig 12;

Fig 14 is a schematic representation of another portion of the frame useable with suitable for use in forming the articles of Fig 1 1 and Fig 12;

Fig 15 is a photograph of an end view of a stack of building panels showing details of the joint;

Fig 16 is a photograph of an assembled pair of building panels according to the invention; Fig 17 is a photograph of a side view of the stack of building panels as shown in Fig 15; Fig 18 is an enlarged photograph of a side view of a stack of building panels according to the invention;

Fig 19 is a photograph taken fro a top view of two assembled panels according to the invention;

Fig 20 is an enlarged photograph of a portion of Fig 19;

Fig 21 is a photograph of an edge of a building panel illustrating the edge configuration thereof;

Fig 22 is a photograph of an end view of the building panel of Fig 21 ;

Fig 23 is a schematic representation of a pair of assembled building panels according to the invention further illustrating a void adjacent the joint between the panels where an electrical wire or cable is located;

Fig 24 is a schematic, partially sectioned view of a ligno-cellulose conduit according to the present Invention for receiving an electrical wire or cable; and,

Fig 25 is an end view of a ligno-cellulose conduit according to the present invention for receiving an electrical wire or cable. Detailed Description of the Preferred Embodiments

As shown in Figs 1-4 are several embodiments of assembled panels according to the invention in which a left hand panel 1 is joined to a right hand panel 2 (in various figures, the same numeral is employed to identify similar elements for ease in understanding the invention).

A tongue 3, provided with locking protrusions 4, 5 joins with a groove portio of panel 2 in Fig 1. The groove portion of panel 2 is not only provided with receiving depressions to receive protrusions 4, 5 by itself may also have prolusions 6, 7 to engage the tongue to prevent undesired disengagement, of the joined tongue and groove.

A disassembled pair of panels (Figs 5a and 5b) may illustrate these elements more clearly. Here it can be seen that groove 8 with recesses 9, 10 to receive protrusions 4', 5' also has protrusions 6\ 7' to engage depressions I I , 12 on the tongue of panel 1.

in some embodiments a stabilizing portion 13 of tongue 3 may extend further into the groove of panel 2 (See Fig 2). Alternatively the distal portion of tongue 3 may be provided with a unique configuration 14 as shown in Fig 5a; 15 as shown in Fig 6a; or 16 as shown i Fig 7.

Fig 8 illustrates an I-beam 20, having an upper flange 21 , a lower flange 22 and connected by a plurality of panels 23a, 23 b, 23c, 23d, 23e and 23f. Joint configurations as shown in any of Figs. 1-7, or other may be used to form the I-beam. Of course, the panels 23a- 23 f may be greater or lesser in number than that actually illustrated being as little as a single panel. They can be made any length, any width, any thickness and are stable in ail dimensions.

Fig 9 illustrates a roofing system 25 having a panel 26 comprised of individual panels 26a, 26b, 26c, 26d, 26e, 26f prejoined to one another by the joints according to any one of Figs.1-7, or other joints, such that it may easily be assembled to panel 27. formed of prejoined individual panels 27a, 27b, 27c, 27d, 27e, 27f joined by any of the joints of Figs, 1-7 or other joints. Thus, the individual panels can be prejoined at a site remote from the actual roof being installed, for example at a factory, or even a work site adjacent the actual roof being installed. As such, the roofing worker installing the roof can cover much more area of the roof quickly than if he had to assemble each individual panel. The individual panels can be made to any- desired dimensions from those simulating conventional asphalt shingles to unique and fanciful patterns for advertising, or other decorative effect. They can be made long to simulate metal roofing styles, can be made with or without embossed surfaces to simulate or not simulate conventional shingles, can be overlapping, or not, as desired. Although illustrated as being installed in the vertical orientation, they can be installed horizontally or at an angle in between horizontal and vertical, The panel 26 is light in weight and can be installed with staples or conventional fasteners.

Fig 10 illustrates an alternate embodiment of a pane! 30 formed of preassembied individual panels 31a, 31b. 31c, 3 Id, 31e, 3 If which might find utility as a door, siding, or other large panel building component. As with Fig 9, the individual panel may be prcjoined with joining parts as in Figs. 1-7. or other joints to form panel 30.

Fig 1 1 shows a cabinet front 40 formed of a mirrored portion 41 and 42, surrounded by their own frames 43 and 44, respectively. The frames can be formed of building frame sections 50, 51 (Figs. 13-14) to form inside comers to receive mirrors 41. 42. Alternatively window 60 (Fig 12) may be surrounded by a building frame 61 formed of frame portions made according to the invention.

Figs. 15 , 17, 18 are photographs of stacked building panels according to the invention.

Fig 16 is a photograph of assembled right and left hand panels 70, 71 showing the joint 72 between the panels.

Fig 19 is a photograph taken from the top of a pair of panels according to the invention assembled together with Fig 20 being an enlarged photograph of the same panels. The joint between the panels is not visible.

Figs. 21 and 22 show a composite panel with multiple joining configurations.

Fig 23 illustrates a pair of assembled panels 80, 81 according to the invention having an electrical wire or cable 82 inserted into a void 83 adjacent the joint between the panels.

Fig 24 illustrates a conduit 90, having a void 91 to accept an electrical wire or cable (not shown in this Figure). The conduit 90 may be made of sections 92, each section having a joining element 93, 94, so as to be able to join to another section. The wire may be uninsulated (or carry conventional insulation) as the composition and structure of the alkali-metal silicate impregnated and heat/radiation treated conduit is insulating (non-conductive) of electricity.

Fig 25 is schematic end view of a conduit 100 formed of two sections 101 , 102 joined by tongue and groove joints 103, 104, The joints 103, 104 in this view are schematic only and may take other forms. Additionally, the conduit may be formed of a greater number of sections than illustrated,: and may, in the case of an extruded section, be formed of only a single section in the circumferential direction ,

The inventive panels, and panels created by the processes and methods of this invention have the further advantages of strength (resistance to rupture) that is increased as much as 5 times that of unmodified Hgno-cellulosic materials without an increase in brittieness.

Further advantages include, but are not limited to, the advantage that these stronger panels can be thinner (using less material) and can span far greater distances, while maintaining wall strength, and also possess greatly improved fastener strength. The inventive panels and panels produced by the methods described herein can. be used to span distances in walls and ceilings of 7 feet and more, with ranges from 4 to 20 feet depending on the use. in one preferred embodiment, panels 34 feet in length and ranging from 4 to 9 feet in width are used to span columns and wall studs spaced 7 feet on center. The thinner, stronger panels of the invention create lighter structures that are far less expensive to construct. Floor panels of the embodiment can be used to span up to 4-foot center on center joist distances for a panel thickness equivalent to conventional panels which are normal h- supported by joists on 16 or 24 inch center to center. Alternatively stated, thinner building panels can be used with conventional 16 or 24 inch center on center support.

In another embodiment, the panels of the invention and panels created by the processes and methods of this invention have the advantages of being able to accept extra attached weight. For example, pictures and the like can. be attached to wall panels without needing bracing from a stud inside the walls.

Another embodiment provides improved resistance to splitting. Alkali metal silicate acts as an adhesive and reinforcement within the fibers of the ligno-celluiosic materials, binding them together, so that thinner pieces can withstand forces that would split other types of materials.

A further result is the production of an advantageous building material that provides buildings that are stronger, lighter, weigh less, can be built taller, and that maintain improved strength and resilience, all at greatly reduce costs of construction.

Having described my invention, it will, be apparent that the invention may take other embodiments than those specifically described and illustrated and may be modified by those skilled in the art without departing from the spirit and scope of the invention described and illustrated by me herein.

Claims

I CLAIM:

1. A building panel formed of a ligno-cellulosic material comprising

a. a ligno-cellulosic material impregnated with an alkali-metal silicate which as been polymerized and rendered water insoluble to form a building panel with edges;

b. at least one of the edges being provided with a joining element selected from the group consisting of a tongue or groove with an integral locking element,

2. The building panel of claim 3 , wherein the Ugno-cellulosic materia! is one selected from the group consisting of natural wood, wood fibers, wood particles, wood chips, wood strands, wood slivers, wood veneers, flax, jute, hemp, ramie, kenaf, straw, bagasse, bark, bamboo and combinations thereof.

3. The building panel of ciaim 1 , wherein a void for receiving an electrically conducting wire or cable is adjacent the. joining element; and, further comprising an electrically conducting wire o cable in the void.

4. The building panel of claim 1 , wherein a void for receiving an electrically conducting wire or cable is remote from the joining element; and further comprising an electrically conducting wire or cable in the void.

5. The building panel of claim 1, wherein the building panel is a core for a decorative surface element.

6. The building panel of claim 5, further comprising a decorative surface on a face of the panel.

7. The building panel of claim 6, wherein the decorative surface element is at least one selected from the group consisting of a laminate, a wood veneer, a metal cladding, glass, ceramic, fabric, cork, rubber and vinyl.

8. The building panel of claim 1, wherein the ligno-ceilulosic material is one selected from the group consisting of wood fibers, wood particles, wood chips, wood strands, wood slivers, wood veneers, flax, jute, hemp, ramie, kenaf, straw, bagasse, bark, bamboo and combinations thereof; and further comprising a non-organic filler,

9. The building panel of claim 8, wherein the non-organic filler is at least one selected from the group consisting of ground marble, mica, stone chips, stone dust, sand and lime.

10. The building panel of claim 8, wherein the building panel is a core for a decorative surface element.

1 1. The building panel of claim 1, wherein the panel has a plurality of edges and each edge comprises at least one joining element.

12. The building panel of claim 1 , wherein the alkali-metal silicate is sodium silicate.

13. A system of building panels comprising a plurality of the building panels of claim 1.

14. A product formed of a ligno-cellulosic material comprising a, iigno-cel osic material impregnated with an alkali -metal silicate which has been rendered water insoluble to form a product with edges; b. at least one of the edges being provided with a joining element selected from the group consisting of a tongue or groove with an integral locking element; wherein the product is at least one selected from the group consisting of a floor panel, a ceiling panel, a wall panel, a floor joist, a roof joist, roofing panels, a sheathing panel, siding, a post, a railings, decking, wainscoting, a fence component, a piling, furniture, cabinetry, window frames, I-beam, glue lam structure and fixtures.

15. A building system comprising a plurality of the products of claim 14,

16. A method of forming a building product from a least two pieces, the process comprising:

a. providing a ligno-celiulosic material impregnated with an alkali-metal silicate which has been rendered water insoluble to form a first building component with edges;

b. pro viding at least one of the edges with a joining element selected from the group consisting of a tongue or groove with an integral locking element;

c. providing a second component with at least an edge to join with said at least one edge of the first component; and,

d. assembling the edge of the first component with the edge of the second component to form a joint and activating the locking element to form the building product.

17. The method of clai 16, further comprising providing a void in at least one of the .first and second components to receive an electrically conductive wire or cable; and, providing an electrically conductive wire or cable in the void.

18. The method of claim 17, wherein the void is in or adjacent to the joint.

19. The method of claim 17, wherein the void is remote from the joint. The method of claim 17, wherein each of the first and second components contain a void and farther comprising placing, an electrically conducting wire or cable in each of the voids.

The method of claim 16, wherein the alkali -metal, silicate is sodium silicate.