IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
UP-0297426
(2005-12-09)
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등록번호 |
US-7849648
(2011-02-10)
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발명자
/ 주소 |
- Tonyan, Timothy D.
- Ullett, James M.
- Reicherts, James E.
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출원인 / 주소 |
- United States Gypsum Company
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대리인 / 주소 |
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인용정보 |
피인용 횟수 :
12 인용 특허 :
53 |
초록
▼
A flooring system including horizontal metal framing members, for example, C-joists, U-joists, open web joists, HAMBRO or other metal frame systems that support a reinforced, lightweight, dimensionally stable SCP panel. The flooring system is non-combustible, water durable, mold and rot resistant, t
A flooring system including horizontal metal framing members, for example, C-joists, U-joists, open web joists, HAMBRO or other metal frame systems that support a reinforced, lightweight, dimensionally stable SCP panel. The flooring system is non-combustible, water durable, mold and rot resistant, termite resistant and is capable of resisting shear loads equal to or exceeding shear loads provided by plywood or oriented strand board panels. The panels employ one or more layers of a continuous phase resulting from the curing of an aqueous mixture of inorganic binder, for example, calcium sulfate alpha hemihydrate, hydraulic cement, an active pozzolan and lime. The continuous phase is reinforced with glass fibers and contains lightweight filler particles, for example, ceramic microspheres.
대표청구항
▼
What is claimed is: 1. A non-combustible flooring system for construction comprising: metal screw fasteners with winged drillers; a metal frame; a horizontal shear diaphragm fastened by the fasteners to the metal frame, the horizontal shear diaphragm comprising a reinforced, lightweight, dimensiona
What is claimed is: 1. A non-combustible flooring system for construction comprising: metal screw fasteners with winged drillers; a metal frame; a horizontal shear diaphragm fastened by the fasteners to the metal frame, the horizontal shear diaphragm comprising a reinforced, lightweight, dimensionally stable cementitious panel; the cementitious panel having a density of 65 to 90 pounds per cubic foot and capable of resisting shear loads when fastened to the metal frame and comprising a continuous phase resulting from the curing of an aqueous mixture comprising, on a dry basis, 49 to 68 weight % of a blend of reactive powders, 23 to 36.1 weight % uniformly distributed lightweight filler particles, and 5 to 20 weight % uniformly distributed alkali-resistant glass fibers, and optional superplasticizer; the continuous phase being uniformly reinforced with the glass fibers and uniformly containing the lightweight filler particles, the lightweight filler particles comprising ceramic microspheres and optionally at least one member selected from the group consisting of glass microspheres, fly ash cenospheres or perlite, each on a dry basis, the lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers), a layer of Type X fire rated gypsum wallboard attached to a side of the metal frame opposed to the shear diaphragm to form a second diaphragm, wherein the winged drillers are located above the point and below the first threads of the screw and protrude laterally from a shaft of the screw, and wherein the flooring system meets the 2 hour fire resistance test rating under ASTM E-119 (effective 2003), wherein the blend of reactive powders comprises, on a dry basis, 45 to 75 wt. % calcium sulfate alpha hemihydrate, 20 to 40 wt. % Portland cement, 0.2 to 3.5 wt. % lime, and 5 to 25 wt. % of an active pozzolan comprising silica fume, wherein the flooring system has a horizontal design shear capacity of the floor shear diaphragm of 300 to 1000 pounds per linear foot, wherein the cementitious panel has a thickness of about ½ to 1½ inches. 2. The system of claim 1, wherein the glass fibers have a diameter of about 10 to 15 microns and lengths of 1 to 2 inches, and the aqueous mixture comprises, on a wet basis, 12.2-12.3 weight % portland cement, 24.4-24.7 weight % calcium sulfate alpha hemihydrate, 5.1 weight % silica fume, 0.4 weight % lime, 26.4-27.4 weight % ceramic microspheres, 1.9 weight % superplasticizer, 21.9-24.2 weight % water, and 4.4-7.2 weight % alkali-resistant glass fibers. 3. The system of claim 1, wherein the ceramic microspheres have at least one feature selected from the group consisting of a mean particle size from 50 to 250 microns and a particle size range of 10 to 500 microns. 4. The system of claim 1, wherein the aqueous mixture the panel has been formed from consists of, on a dry basis: 58 to 68 wt. % said reactive powders, 6 to 17 wt. % said alkali-resistant glass fibers, and 23 to 34 wt. % said lightweight filler particles, and optional said superplasticizer; wherein said lightweight filler particles consist of ceramic microspheres and up to 1.0 wt. % filler particles selected from the group consisting of glass microspheres, fly ash cenospheres or perlite, wherein the reactive powders consist of, on a dry basis: 65 to 75 wt. % calcium sulfate alpha hemihydrate, 20 to 25 wt. % Portland cement, 0.75 to 1.25 wt. % lime, and 10 to 15 wt. % silica fume active pozzolan. 5. The system of claim 4, wherein the aqueous mixture contains, on a dry basis, 7 to 12 wt. % alkali-resistant glass fibers, wherein the horizontal shear diaphragm is supported on light gauge cold rolled metal frame comprising metal joists. 6. The system of claim 5, wherein the ceramic microspheres have at least one feature selected from the group consisting of a mean particle size from 50 to 250 microns and falling within a particle size range of 10 to 500 microns, wherein the panels are ½ inch (12.5 mm) thick, and the system having the ½ inch (12.5 mm) thick panels fastened to said light gauge cold rolled metal frame when tested according to ASTM D-1761-88, effective 1988 (reapproved 2000), has a dry lateral screw resistance of 350 to 550 pounds, wherein the glass fibers are monofilaments having a diameter of about 5 to 25 microns (micrometers) and a length of about 0.25 to 3 inches (6.3 to 76 mm), wherein the flexural strength of a said panel having a dry density of 65 lb/ft3 to 95 lb/ft3 (1041 to 1522 kg/m3) after being soaked in water for 48 hours is at least 1650 psi (11.4 MPa) as measured by the ASTM C 947-03 test, effective 2003, wherein the system has a horizontal design shear capacity of the floor diaphragm of 400 to 1000 pounds per linear foot. 7. The system of claim 6, wherein the metal frame is 16 gauge steel. 8. The system of claim 1, wherein the filler comprises the ceramic microspheres and optionally at least one member selected from the group consisting of uniformly distributed glass microspheres and fly ash cenospheres having an average diameter of about 10 to 350 microns (micrometers) and, wherein the glass fibers are monofilaments having a diameter of about 5 to 25 microns (micrometers) and a length of about 0.25 to 3 inches (6.3 to 76 mm). 9. The system of claim 1, wherein the aqueous mixture comprises, on a dry basis: 54 to 58 wt. % said reactive powders, 5 to 15 wt. % said glass fibers, 33.8 to 36.1 wt. % said lightweight filler particles consisting of ceramic microspheres, and up to 1.0 wt. % of the glass microspheres, the ceramic microspheres having a particle density of 0.50 to 0.80 g/mL; and optional superplasticizer. 10. The system of claim 1, wherein the panel comprises a core comprising the continuous phase resulting from the curing of the aqueous mixture, and further comprising at least one outer layer, each said outer layer comprising a second continuous phase resulting from the curing of a second aqueous mixture comprising, on a dry basis, 49 to 68 weight % a second blend of reactive powders, 23 to 36.1 weight % uniformly distributed lightweight filler particles comprising uniformly distributed ceramic microspheres, and 5 to 20 weight % uniformly distributed alkali-resistant glass fibers, and optional superplasticizer, the second blend of reactive powders comprising, on a dry basis, 45 to 75 wt. % calcium sulfate alpha hemihydrate, 20 to 40 wt. % Portland cement, 0.2 to 3.5 wt. % lime, and 5 to 25 wt. % of an active pozzolan comprising silica fume, the second continuous phase being uniformly reinforced with the alkali-resistant glass fibers, and the lightweight filler particles comprising ceramic microspheres having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers), at least one outer layer having reduced phase density relative to the core. 11. The system of claim 10, wherein the second aqueous mixture the outer layer(s) has been formed from comprises, each on a dry basis: 58 to 68 wt. % said second blend of reactive powders, 6 to 17 wt. % said glass fibers and 23 to 34 wt. % said lightweight filler particles comprising ceramic microspheres and up to 1.0 wt. % of glass microspheres having an average diameter of about 10 to 350 microns (micrometers), and optional superplasticizer. 12. The system of claim 1, wherein the cementitious panel has a thickness of ¾ inch and the ¾ inch (19 mm) thick panel when tested according to ASTM 661-88 and APA S-1 test methods, effective as of 1988 (reapproved 1997) and Aug. 12, 1980, respectively, over a span of 16 inches (406.4 mm) on centers, has an ultimate load capacity greater than 400 lb (1810 kg), under static loading, an ultimate load capacity greater than 400 lb (182 kg) under impact loading, and a deflection of less than 0.125 inches (1.98 mm) under both static and impact loading with a 200 lb (90.9 kg) load. 13. The system of claim 1, wherein the flexural strength of a panel having a dry density of 65 lb/ft3 (1041 kg/m3) to 90 lb/ft3 after being soaked in water for 48 hours is at least 1650 psi (11.4 MPa) as measured by the ASTM C 947-03 test, effective as of 2003. 14. The system of claim 1, wherein the blend of reactive powders consists of, on a dry basis: 65 to 75 wt. % calcium sulfate hemihydrate, 20 to 25 wt. % Portland cement, 0.75 to 1.25 wt. % lime, and 10 to 15 wt. % silica fume active pozzolan. 15. The system of claim 1, wherein the panels are ¾ inch (19 mm) thick, and the horizontal shear diaphragm load carrying capacity of the system will not be lessened by more than 25% when exposed to water in a test wherein a 2 inch head of water is maintained over the ¾ inch thick panels fastened on a 10 foot by 20 foot metal frame for a period of 24 hours. 16. The system of claim 1, wherein the panels are ¾ inch (19 mm) thick, and the system will not absorb more than 0.7 pounds per square foot of water when exposed to water in a test wherein a 2 inch head of water is maintained over the ¾ inch thick panels fastened on a 10 foot by 20 foot metal frame for a period of 24 hours. 17. The system of claim 1, wherein the panels are ¾ inch (19 mm) thick, and a 10 foot wide by 20 foot long by ¾ inch thick diaphragm of the panels attached to a 10 foot by 20 foot said metal frame will not swell more than 5% when exposed to a 2 inch head of water maintained over the panels fastened on the metal frame for a period of 24 hours. 18. The system of claim 1, wherein the panel comprises: a core layer comprising the continuous phase, the continuous phase comprising 5 to 17 wt % glass fibers, on a dry basis, and at least one outer layer of respectively a second continuous phase resulting from the curing of a second aqueous mixture comprising, on a dry basis, 49 to 68 weight % second blend of reactive powder, 23 to 36.1 weight percent lightweight filler comprising ceramic microspheres, and 7 to 20 weight % alkali-resistant glass fibers, and optional superplasticizer; the second blend of reactive powders consisting of, on a dry basis, 45 to 75 wt. % calcium sulfate alpha hemihydrate, 20 to 40 wt. % Portland cement, 0.2 to 3.5 wt. % lime, and 5 to 25 wt. % of silica fume, the second continuous phase being reinforced with glass fibers and containing the lightweight filler particles, the lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers) on each opposed side of the inner layer, wherein the at least one outer layer has a higher percentage of glass fibers than the inner layer. 19. The system of claim 1, wherein, the system is non-directional, in that the panels of the system may be placed with their long dimension parallel or perpendicular to the metal joists of the frame without losing strength or load carrying characteristics, wherein the ability of the system to support dead and live loads without failure is the same regardless of the orientation of the SCP panel on the metal framing. 20. The system of claim 1, wherein the system has a horizontal design shear capacity of the floor diaphragm of 400 to 800 pounds per linear foot. 21. The system of claim 1, wherein the horizontal shear diaphragm is supported on light gauge cold rolled metal frame comprising metal joists. 22. The system of claim 1, wherein the light gauge cold rolled metal frame comprises a corrugated metal sheet. 23. The system of claim 1, wherein the metal screw fasteners with winged drillers are winged self-drilling screws. 24. The system of claim 1, wherein the panels are ½ inch (12.5 mm) thick, and the system having the ½ inch (12.5 mm) thick panels fastened to said light gauge cold rolled metal frame when tested according to ASTM D-1761-88, effective 1988 (reapproved 2000), has a dry lateral screw resistance of 350 to 550 pounds. 25. The system of claim 1, wherein the panels are ¾ inch (19.05 mm) thick, and the system having the ¾ inch (19.05 mm) thick panels fastened to said light gauge cold rolled metal frame when tested according to ASTM D-1761-88, effective 1988 (reapproved 2000), has a dry lateral screw resistance of 400 to 500 pounds. 26. A method of providing a 2 hour fire resistance test rating under ASTM E-119, effective 2003 to a building structure comprising: making a non-combustible flooring system as flooring of the building structure, said making step comprising forming a horizontal shear diaphragm supported on a metal frame, the system comprising: metal bugle head screw fasteners with winged drillers; the metal frame; the horizontal shear diaphragm fastened by the fasteners to the metal frame, the horizontal shear diaphragm comprising the reinforced, lightweight, dimensionally stable structural cementitious panel; the cementitious panel having a density of 65 to 90 pounds per cubic foot and capable of resisting shear loads when fastened to the metal frame and comprising a continuous phase resulting from the curing of an aqueous mixture comprising, on a dry basis. 49 to 68 weight % of a blend of reactive powders, 23 to 36.1 weight % uniformly distributed lightweight filler particles, and 5 to 20 weight % uniformly distributed alkali-resistant glass fibers, and optional superplasticizer; the continuous phase being uniformly reinforced with the glass fibers and uniformly containing the lightweight filler particles, the lightweight filler particles comprising ceramic microspheres and optionally at least one member selected from the group consisting of glass microspheres, fly ash cenospheres or perlite, each on a dry basis, the lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers), a layer of Type X fire rated gypsum wallboard attached to a side of the metal frame opposed to the shear diaphragm to form a second diaphragm, wherein the winged drillers are located above the point and below the first threads of the screw and protrude laterally from a shaft of the screw, and wherein the flooring system meets the 2 hour fire resistance test rating under ASTM E-119 (effective 2003), wherein the blend of reactive powders comprises, on a dry basis, 45 to 75 wt. % calcium sulfate alpha hemihydrate, 20 to 40 wt. % Portland cement, 0.2 to 3.5 wt. % lime, and 5 to 25 wt. % of an active pozzolan comprising silica fume, wherein the flooring system has a horizontal design shear capacity of the floor shear diaphragm of 300 to 1000 pounds per linear foot, and the frame comprising metal joists, said forming comprising: placing the panel on metal joists of the metal frame; attaching the structural cementitious panel on the metal joists with bugle head screws with winged drillers, the winged drillers located above the point and below the threads of the screw and protruding laterally from a shaft of the screw; and attaching the layer of Type X fire rated gypsum wallboard to the side of the frame opposed to said horizontal shear diaphragm to form a second horizontal diaphragm, wherein the flooring system meets the 2 hour fire resistance test rating under ASTM E-119 (effective 2003), the cementitious panel has a thickness of about ½ inch to 1 ½ inches. 27. The method of making the non-combustible flooring system of claim 26, comprising placing the panel on said metal joists when the ambient temperature is less than 32 degrees F. (0 degrees C.), wherein the panel has a thickness of about ¼ inch to 1 ½ inches (6.3 to 38.11 mm), wherein the flexural strength of the panel having a dry density of 65 lb/ft3 (1041 kg/m3) to 90 lb/ft3 after being soaked in water for 48 hours is at least 1650 psi (11.4 MPa) as measured by the ASTM C 947-03 test, effective as of 2003. 28. The method of claim 26, comprising placing the panel on said metal joists when the ambient temperature is less than 20 degrees F. (minus 7.5 degrees C.), wherein the panels are ¾ inch (19 mm), and the horizontal shear diaphragm load carrying capacity of the system will not be lessened by more than 25% when exposed to water in a test wherein a 2 inch head of water is maintained over the ¾ inch thick panels fastened on a 10 foot by 20 foot metal frame for a period of 24 hours, wherein the ¾ inch (19 mm) thick panel when tested according to ASTM 661-88 and APA S-1 test methods, effective as of 1988 (reapproved 1997) and Aug. 12, 1980, respectively, over a span of 16 inches (406.4 mm) on centers, has an ultimate load capacity greater than 400 lb (1810 kg), under static loading, an ultimate load capacity greater than 400 lb (182 kg) under impact loading, and a deflection of less than 0.125 inches (1.98 mm) under both static and impact loading with a 200 lb (90.9 kg) load. 29. The method of claim 26, wherein said placing step comprises placing the panel to lie on said metal joists when the ambient temperature is less than 32 degrees F. (0 degrees C.) by dropping the panel on the metal framing elements such that at least one end of the panel falls at least 2 feet. 30. The method of claim 26, wherein said placing step comprises placing the panel to lie on said metal joists when the ambient temperature is less than 32 degrees F. (0 degrees C.) by dropping the panel on the metal framing elements such that at least one end of the panel falls 2 to 3 feet. 31. The method of claim 26, wherein the metal screw fasteners with winged drillers are winged self-drilling screws. 32. The method of claim 26, wherein water is added to form the aqueous mixture in a range of between 35 to 70% of the weight of reactive powder. 33. The method of claim 26, wherein water is added to form the aqueous mixture in a range of between 60 to 70% of the weight of reactive powder. 34. The method of claim 26, wherein the aqueous mixture consists of, on a dry basis: 58 to 68 wt. % reactive powders, 6 to 17 wt. % alkali-resistant glass fibers, and 23 to 34 wt. % lightweight filler particles, and optional superplasticizer; wherein said lightweight filler particles consist of ceramic microspheres and up to 1.0 wt. % filler particles selected from the group consisting of glass microspheres, fly ash cenospheres or perlite, wherein the reactive powders consist of, on a dry basis: 65 to 75 wt. % calcium sulfate alpha hemihydrate, 20 to 25 wt. % Portland cement, 0.75 to 1.25 wt. % lime, and 10 to 15 wt. % silica fume active pozzolan. 35. The method of claim 34, wherein the aqueous mixture contains 7 to 12 wt. % alkali-resistant glass fibers, wherein the horizontal shear diaphragm is supported on light gauge cold rolled metal frame comprising metal joists. 36. The method of claim 34, wherein water is added to form the aqueous mixture in a range of between 35 to 70% of the weight of reactive powder. 37. The method of claim 34, wherein the ceramic microspheres have at least one feature selected from the group consisting of a mean particle size from 50 to 250 microns and falling within a particle size range of 10 to 500 microns, wherein the panels are ½ inch (12.5 mm) thick, and the system having the ½ inch (12.5 mm) thick panels fastened to said light gauge cold rolled metal frame when tested according to ASTM D-1761-88, effective 1988 (reapproved 2000), has a dry lateral screw resistance of 350 to 550 pounds, wherein the glass fibers are monofilaments having a diameter of about 5 to 25 microns (micrometers) and a length of about 0.25 to 3 inches (6.3 to 76 mm), wherein the flexural strength of a said panel having a dry density of 65 lb/ft3 to 95 lb/ft3 (1041 to 1522 kg/m3) after being soaked in water for 48 hours is at least 1650 psi (11.4 MPa) as measured by the ASTM C 947-03 test, effective 2003, wherein the system has a horizontal design shear capacity of the floor diaphragm of 400 to 1000 pounds per linear foot, wherein the metal frame is 16 gauge steel. 38. The method of claim 26, wherein the aqueous mixture comprises, on a dry basis: 54 to 58 wt. % of the reactive powders, 5 to 15 wt. % of the glass fibers, 33.8 to 36.1 wt. % of the lightweight filler particles consisting of ceramic spheres with up to 1.0 wt. % of the glass microspheres, the ceramic microspheres having a particle density of 0.50 to 0.80 g/mL, each on a dry basis; and optional superplasticizer.
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