Ultra stable structural laminate

Patent metadata

Field	Value
Publication number	US-12454487-B2
Application number	US-202318167310-A
Country	US
Kind code	B2
Filing date	Feb 10, 2023
Priority date	Nov 7, 2017
Publication date	Oct 28, 2025
Grant date	Oct 28, 2025

Abstract

An ultra-stable structural laminate with fire resistance and a lateral nail pull strength from 44 to 300 pounds of force and an insulation R value from 1 to 40, the ultra-stable structural laminate of a cementitious material with a nano-molecular veneer and a foam component catalytically reacted into an expanded closed cell foam having a thickness from ⅛ th inch to 8 inches, a density from 1.5 pounds/cubic foot to 3 pounds/cubic foot that self-adheres to the cementitious material forming an ultra-stable structural laminate with fire resistance and a lateral nail pull strength from 44 pounds to 300 pounds of force, an insulation R value from 1 to 40, a resistance to seismic impact for earthquakes over 3.1 on the Richter Scale, a break point from 7 lbs/inch to 100 lbs/inch; and a resistance to wind shear equivalent to a 15 mph downburst.

First claim

What is claimed is:

1. A structural laminate comprising a substrate coated by a cementitious material, wherein:
the cementitious material comprises magnesium oxychloride crystals encapsulated with a phosphorus-containing amorphous layer; and
the substrate is selected from the group consisting of oriented strand board, plywood, waterproof membrane, concrete, and wood.

2. The structural laminate of claim 1 , wherein the phosphorus-containing amorphous layer is substantially free of crystalline silica.

3. The structural laminate of claim 1 , wherein the phosphorus-containing amorphous layer is in the form of an amorphous nano-molecular veneer comprising non-crystalline, phosphorus-containing species identifiable by elemental analysis utilizing a scanning electron microscope (SEM).

4. The structural laminate of claim 3 , wherein at least a portion of the nano-molecular veneer is insoluble in water.

5. The structural laminate of claim 1 , wherein the cementitious material is substantially free of magnesium phosphate.

6. The structural laminate of claim 1 , wherein the magnesium oxychloride crystals constitute from about 45 wt % to about 85 wt % of the cementitious material, as determined by X-Ray Diffraction.

7. The structural laminate of claim 1 , wherein the cementitious material further comprises from 0.1 wt % to 30 wt % of aggregate based on the total weight of the material.

8. The structural laminate of claim 7 , wherein the aggregate is selected from the group consisting of wood, perlite, styrene based foam beads, calcium carbonate powder, glass particulate, and combinations thereof.

9. The structural laminate of claim 1 , wherein the cementitious material further comprises from 0.1 wt % to 2 wt % of a reinforcing material based on the total weight of the material.

10. The structural laminate of claim 9 , wherein the reinforcing material is selected from the group consisting of non-woven silica-containing mat, woven silica-containing mat, non-woven hydrocarbon-containing mat and woven hydrocarbon-containing mat.

11. The structural laminate of claim 1 , wherein the cementitious material further comprises from 0.1 wt % to 15 wt % of biomass based on the total weight of the material.

12. The cementitious material of claim 11 , wherein the biomass is selected from the group consisting of rice husks, corn husks and dung.

13. The structural laminate of claim 1 , wherein the cementitious material further comprises from 0.1 wt % to 10 wt % of at least one surfactant based on the total weight of the material.

14. The structural laminate of claim 1 , wherein the cementitious material further comprises from 0.1 wt % to 5 wt % of a re-dispersible powder polymer based on the final total weight of the material.

15. The structural laminate of claim 14 , wherein the re-dispersible powder is selected from the group consisting of silicon, polyurethane dispersion, polyurethane, alkyl carboxylic acid vinyl ester monomer, branched and unbranched alcohol(meth)acrylic acid ester monomer, vinyl aromatic monomer, olefin monomer, diene monomer, vinyl halide monomer and vinyl acetate ethylene (VAE).

16. The structural laminate of claim 1 , wherein the cementitious material further comprises from 0.1 wt % to 5 wt % of an acrylic or styrene butadiene rubber (SBR) based on the total final weight of the material.

17. The structural laminate of claim 1 , wherein the cementitious material further comprises from 0.1 wt % to 15 wt % of a reinforcing material based on the total weight of the material.

18. The structural laminate of claim 17 , wherein the reinforcing material is selected from the group consisting of chopped silica containing fibers, hemp containing fibers, nano-molecular carbon fiber strands, chopped carbon fibers, chopped hydrocarbon fibers, and combinations thereof.

19. The structural laminate of claim 1 wherein the substrate is oriented strand board.

20. The structural laminate of claim 19 in the form of a board for structural assembly to form facilities, offices, barns, homes, fences, and marine quarters for use on a ship or oil platform offshore.

Assignees

• Mitek Holdings Inc

Inventors

• Wambaugh James A
• Rochner Brett
• Weinberger Cole J

Classifications

• C04B9/04

  Magnesium cements containing sulfates, nitrates, phosphates or fluorides · CPC title

• B32B2266/0228

  Aromatic vinyl resin, e.g. styrenic (co)polymers · CPC title

• B32B2266/0278

  Polyurethane · CPC title

• B32B2266/08

  Closed cell foam · CPC title

• B32B5/18

  characterised by features of a layer {of} foamed material · CPC title