IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
UP-0321069
(2005-12-30)
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등록번호 |
US-7849649
(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 :
11 인용 특허 :
53 |
초록
▼
A vertical shear wall system including vertical metal framing members, for example, C-joists, U-joists, open web joists, or other metal frame systems that support a reinforced, lightweight, dimensionally stable SCP panel. The shear wall system is non-combustible, water durable, mold and rot resistan
A vertical shear wall system including vertical metal framing members, for example, C-joists, U-joists, open web joists, or other metal frame systems that support a reinforced, lightweight, dimensionally stable SCP panel. The shear wall 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 shear wall system for construction comprising: metal screw fasteners with winged drillers wherein the winged drillers are located above the point and below the first thread of the screw and protrude laterally from a shaft of the screw; light gauge cold rolle
What is claimed is: 1. A non-combustible shear wall system for construction comprising: metal screw fasteners with winged drillers wherein the winged drillers are located above the point and below the first thread of the screw and protrude laterally from a shaft of the screw; light gauge cold rolled metal frame; a vertical shear diaphragm fastened by the fasteners to the light gauge cold rolled metal frame, the vertical shear diaphragm comprising a reinforced, lightweight, dimensionally stable cementitious panel and the frame comprising metal studs; the panel having a density of 65 to 90 pounds per cubic foot and capable of resisting shear loads when fastened to framing 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 35 weight % uniformly distributed lightweight filler, and 5 to 20 weight % alkali-resistant glass fibers, and optional superplasticizer; the continuous phase being uniformly reinforced with 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 and perlite, 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), wherein the reactive powders comprise, on a dry basis, 45 to 75 wt % calcium sulfate alpha hemihydrates, 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 panels are ⅜-¾ inch (9-19 mm) thick, and the system having the ⅜-¾ inch (9-19 mm) thick panels fastened to laterally braced said light gauge cold rolled metal frame when tested according to ASTM E-72-05, effective 2005, has a nominal wall shear capacity of 400 to 1200 pounds per linear foot, wherein the 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 shear wall system further comprises a layer of Type X fire rated gypsum wallboard attached to a side of the metal framing opposed to said shear diaphragm panel to form a second diaphragm, and wherein Type X fire rated gypsum wallboard are only on the one side of the frame opposed to the shear diaphragm, wherein the shear wall system fastened to the metal frame meets the performance of the 2 hour fire resistance test rating under ASTM E-119, effective 2003. 2. The system of claim 1, wherein the aqueous mixture consists of, on a dry basis: 58 to 68 wt % reactive powders, 23 to 35 weight % lightweight filler particles consisting of uniformly distributed ceramic microspheres, 5 to 20 wt. % alkali-resistant glass fibers, and optional plasticizer; the reactive powders consisting 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. % of silica fume active pozzolan. 3. The system of claim 2, 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. 4. The system of claim 2, 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 consisting of, on a dry basis, 58 to 68 weight % of a second blend of reactive powders, 23 to 35 weight percent uniformly distributed lightweight filler, and 5 to 20 weight % alkali-resistant glass fibers, and optional superplasticizer; the second blend of reactive powders consisting 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. % 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. 5. The system of claim 4, wherein the outer layer(s) has been formed from 54 to 68 wt. % of the second blend of reactive powders, 5 to 15 wt. % of the glass fibers, up to 1.0 wt. % of glass microspheres having an average diameter of about 10 to 350 microns (micrometers), and 23 to 35 wt. % of the lightweight filler particles comprising ceramic spheres, each on a dry basis. 6. The system of claim 4, wherein the at least one outer layer has a thickness of about 1/32 to 4/32 inches (0.8 to 3.2 mm). 7. The system of claim 1, wherein the aqueous mixture comprises, on a dry basis: 54 to 68 wt. % of the reactive powders, 6 to 17 wt. % of the glass fibers, and 23 to 35 wt. % of said lightweight filler, each on a dry basis. 8. The system of claim 1, wherein the aqueous mixture comprises, on a dry basis: 56 to 68 wt. % of the reactive powders, 5 to 12 wt. % of the glass fibers, and 35 to 42 wt. % of ceramic microspheres, the ceramic microspheres having a particle density of 0.50 to 0.80 g/mL. 9. The system of claim 1, wherein the filler comprises 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). 10. The system of claim 1, wherein the aqueous mixture comprises, on a dry basis: 54 to 68 wt. % of the reactive powders, 5 to 15 wt. % of the glass fibers, 23 to 35 wt. % of ceramic spheres, and up to 1.0 wt. % of glass microspheres, each on a dry basis. 11. The system of claim 1, wherein the panel has a thickness of about ¼ to 1½ inches (6.3 to 38.11 mm). 12. The system of claim 1, wherein the panels are ⅜-¾ inch (9-19 mm) thick, and the system having the ⅜-¾ inch (9-19 mm) thick panels fastened to laterally braced said light gauge cold rolled metal frame when tested according to ASTM E-72-05, effective 2005, has a nominal wall shear capacity of 800 to 1200 pounds per linear foot. 13. 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 laterally braced said light gauge cold rolled metal frame when tested according to ASTM E-72-05, effective 2005, has a nominal wall shear capacity of 800 to 1200 pounds per linear foot. 14. The system of claim 1, 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). 15. The system of claim 1, 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 1000 psi (7 MPa) as measured by the ASTM C 947-03 test, effective 2003. 16. The system of claim 1, 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. 17. The system of claim 1, wherein the reactive powders comprise, 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. % of an active pozzolan comprising silica fume. 18. The system of claim 1, wherein the at least one said stud comprises a substantially C-shaped member fabricated from metal. 19. The system of claim 1, wherein the panels are ⅜-¾ inch (9-19 mm) thick, and the horizontal shear diaphragm load carrying capacity of the system will not be lessened by more than 20% when exposed to water in a test wherein a 2 inch head of water is maintained over the ⅜-¾ inch thick panels fastened on a 10 foot by 20 foot metal frame for a period of 24 hours, 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 ⅜-¾ inch thick panels fastened on a 10 foot by 20 foot metal frame for a period of 24 hours. 20. The system of claim 1, wherein the panels are ⅜-¾ inch (9-19 mm) thick, and a 10 foot wide by 20 foot long by ⅜-¾ 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 SCP panels fastened on the metal frame for a period of 24 hours. 21. The system of claim 1, wherein every component meets ASTM G-21-96, effective 1996 (reapproved 2002), in which the system achieves approximately a 1 and meets ASTM D-3273-94, effective 1994, in which the system achieves approximately a 10. 22. The system of claim 1, wherein the panel comprises: a core layer comprising the continuous phase, and at least one outer layer of respectively a second continuous phase resulting from the curing of a second aqueous mixture consisting of, on a dry basis, 58 to 68 weight % of said blend of reactive powders, 23 to 35 weight percent uniformly distributed lightweight filler, and 5 to 20 weight % alkali-resistant glass fibers, and optional superplasticizer; the second blend of reactive powders consisting 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. % of an active pozzolan comprising silica fume, the second continuous phase being reinforced with the glass fibers and containing the lightweight filler particles comprising ceramic microspheres, 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. 23. The system of claim 1, wherein the aqueous mixture consists of, on a dry basis: 49 to 68 wt. % of the reactive powders, 23 to 35 wt. % of the lightweight filler ceramic microspheres, the ceramic microspheres having a particle density of 0.50 to 0.80 g/mL, and 7 to 12 wt. % of the alkali-resistant glass fibers, and optional plasticizer; wherein the blend of reactive powders consists of, on a dry basis: 45 to 65 wt. % calcium sulfate alpha hemihydrate, 20 to 40 wt. % Portland cement as the hydraulic cement, 0.2 to 3.5 wt. % lime, and 5 to 12 wt. % of silica fume, active pozzolan, 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 ½-¾ inch thick, and the system having the ½-¾ inch thick panels fastened to laterally braced said light gauge cold rolled metal frame when tested according to ASTM E-72-05, effective, has a nominal wall shear capacity of 800 to 1200 pounds per linear foot, wherein the alkali-resistant 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 at least one said metal stud comprises a substantially C-shaped member fabricated from metal. 24. 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 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. 25. 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. 26. 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. 27. The system of claim 1, wherein the metal studs are 16 gauge steel. 28. A method of improving the fire resistance of a building, comprising: constructing the building to include a non-combustible shear wall system comprising metal screw fasteners with winged drillers wherein the winged drillers are located above the point and below the first thread of the screw and protrude laterally from a shaft of the screw; a light gauge cold rolled metal frame; a vertical shear diaphragm fastened by the fasteners to the light gauge cold rolled metal frame, the vertical shear diaphragm comprising a reinforced, lightweight, dimensionally stable cementitious panel and the frame comprising metal studs; the panel having a density of 65 to 90 pounds per cubic foot and capable of resisting shear loads when fastened to framing 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 35 weight % uniformly distributed lightweight filler, and 5 to 20 weight % alkali-resistant glass fibers, and optional superplasticizer; the continuous phase being uniformly reinforced with 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 and perlite, 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), wherein the reactive powders comprise, on a dry basis, 45 to 75 wt % calcium sulfate alpha hemihydrates, 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 panels are ⅜-¾ inch (9-19 mm) thick, and the system having the ⅜-¾ inch (9-19 mm) thick panels fastened to laterally braced said light gauge cold rolled metal frame when tested according to ASTM E-72-05, effective 2005, has a nominal wall shear capacity of 400 to 1200 pounds per linear foot, wherein the 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 shear wall system further comprises a layer of Type X fire rated gypsum wallboard attached to a side of the metal framing opposed to said shear diaphragm panel to form a second diaphragm, and wherein Type X fire rated gypsum wallboard are only on the one side of the frame opposed to the shear diaphragm, wherein the shear wall system fastened to the metal frame meets the performance of the 2 hour fire resistance test rating under ASTM E-119, effective 2003, the non-combustible shear wall system made by a method comprising: attaching the structural cement panels to one side of said metal studs of the building to form the vertical shear diaphragm as an outer wall of the building and attaching the Type X fire rated gypsum wallboard on the opposed side of said metal studs of the building, wherein the structural cement panels are mechanically fastened to the metal frame with said metal screws with winged driller. 29. The method of claim 28, wherein the metal screw fasteners with winged drillers are winged self-drilling screws. 30. The method of claim 28, wherein the metal studs are gauge steel. 31. The method of claim 28, wherein the panels are ¾ inch thick. 32. The method of claim 28, wherein the aqueous mixture consists of, on a dry basis: 58 to 68 wt % reactive powders, 23 to 35 weight % lightweight filler particles consisting of uniformly distributed ceramic microspheres, and 5 to 20 wt. % alkali-resistant glass fibers, and optional plasticizer; wherein the blend of reactive powders consists 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. % of active pozzolan silica fume. 33. The method of claim 28, wherein the aqueous mixture consists of, on a dry basis: 49 to 68 wt. % of the reactive powders, 23 to 35 wt. % of the lightweight filler ceramic microspheres, the ceramic microspheres having a particle density of 0.50 to 0.80 g/mL, and 7 to 12 wt. % of the alkali-resistant glass fibers, and optional plasticizer; wherein the blend of reactive powders consists of, on a dry basis: 45 to 65 wt. % calcium sulfate alpha hemihydrate, 20 to 40 wt. % Portland cement as the hydraulic cement, 0.2 to 3.5 wt. % lime, and 5 to 12 wt. % of silica fume, active pozzolan, 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 ½-¾ inch thick, and the system having the ½-¾ inch thick panels fastened to laterally braced said light gauge cold rolled metal frame when tested according to ASTM E-72-05, effective, has a nominal wall shear capacity of 800 to 1200 pounds per linear foot, wherein the alkali-resistant 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 at least one said metal stud comprises a substantially C-shaped member fabricated from metal. 34. A method of making a non-combustible shear wall system, the non-combustible shear wall system comprising metal screw fasteners with winged drillers wherein the winged drillers are located above the point and below the first thread of the screw and protrude laterally from a shaft of the screw; a light gauge cold rolled metal frame; a vertical shear diaphragm fastened by the fasteners to the light gauge cold rolled metal frame, the vertical shear diaphragm comprising a reinforced, lightweight, dimensionally stable cementitious panel and the frame comprising metal studs; the panel having a density of 65 to 90 pounds per cubic foot and capable of resisting shear loads when fastened to framing 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 35 weight % uniformly distributed lightweight filler, and 5 to 20 weight % alkali-resistant glass fibers, and optional superplasticizer; the continuous phase being uniformly reinforced with 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 and perlite, 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), wherein the reactive powders comprise, on a dry basis, 45 to 75 wt % calcium sulfate alpha hemihydrates, 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 panels are ⅜-¾ inch (9-19 mm) thick, and the system having the ⅜-¾ inch (9-19 mm) thick panels fastened to laterally braced said light gauge cold rolled metal frame when tested according to ASTM E-72-05, effective 2005, has a nominal wall shear capacity of 400 to 1200 pounds per linear foot, wherein the 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 shear wall system further comprises a layer of Type X fire rated gypsum wallboard attached to a side of the metal framing opposed to said shear diaphragm panel to form a second diaphragm, and wherein Type X fire rated gypsum wallboard are only on the one side of the frame opposed to the shear diaphragm, wherein the shear wall system fastened to the metal frame meets the performance of the 2 hour fire resistance test rating under ASTM E-119, effective 2003, the method further comprising placing the panel on said metal studs, mechanically fastening the panel to the metal frame with said metal screw with winged driller, wherein the placing the panel on elements of said metal frame occurs when the ambient temperature is less than 32 degrees F. (0 degrees C.). 35. The method of claim 34, comprising placing the panel on elements of said metal frame when the ambient temperature is less than 20 degrees F. (minus 7.5 degrees C.). 36. The method of claim 34, wherein said placing step comprises placing the panel to lie horizontally on elements of said metal frame 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 and afterwards reorienting the panel and metal framing elements vertically. 37. The method of claim 34, wherein said placing step comprises placing the panel to lie horizontally on elements of said metal frame 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 3 to 4 feet and afterwards reorienting the panel and metal framing elements vertically. 38. The method of claim 34, wherein the panel is placed vertically on said metal framing elements that are vertically oriented. 39. The method of claim 34, wherein the panel is placed horizontally on said metal framing elements that are horizontally oriented and, after said placing, the panel and metal frame elements are moved to be vertically oriented. 40. The system of claim 1, wherein the metal screw fasteners with winged drillers are winged self-drilling screws.
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