Stock material or miscellaneous articles – Two dimensionally sectional layer – With frame – casing – or perimeter structure
Reexamination Certificate
1998-12-31
2001-05-22
Copenheaver, Blaine (Department: 1771)
Stock material or miscellaneous articles
Two dimensionally sectional layer
With frame, casing, or perimeter structure
C052S309400, C052S309700, C428S052000, C428S061000, C428S081000, C428S223000, C428S304400
Reexamination Certificate
active
06235367
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to a construction composite material used in the manufacture of molded panels used for interior wall erecting panels, exterior wall panels, facade facings and roofing panels for the building of houses, commercial businesses, and industrial facilities, as well as the manufacture of power transmission poles, railroad ties, conduits, sewage piping, insulation barriers for protecting hulls, bulkheads, overheads, and compartments of ships, aircraft, railway tanker cars, tanker trucks, and the like. More particularly, the construction composite material is a bonded composition matrix that includes the unique combination of chemical components having support structures (non-chemical) therein.
BACKGROUND OF THE INVENTION
The demand for housing, electrical power, and sewage removal on a global scale is great. On the continents of South America, Asia, Africa and Eastern Europe the needs are highest. Many people in these areas are without any shelter, electrical power or sewage facilities at all. Where shelter is provided, and/or power and sewage removal, it is usually unsafe, unsanitary and sub-standard even by the lowest possible basic considerations.
Many of these governments and private sector industries cannot meet the demand for these basis improvements. Whether it is due to lack of resources, manpower or technology, they could not even come close to supplying all the housing, electrical power and sanitary sewage facility needs in their respective countries. Then, in an attempt to reduce this problem, they simply build unsafe housing.
There remains a need in these countries for modern day construction of housing and buildings, electrical power and sanitary sewage techniques and materials. Especially, a composite material product that will minimize the use of natural resources, one that is safe, can survive natural disasters, and is able to be built efficiently and timely. Additionally, there is a need to provide the process technology for the manufacturing of such products in underdeveloped countries by producing more efficient building materials.
DESCRIPTION OF THE PRIOR ART
Construction materials having chemical components that include an isocyonate, a styrene, a hydroxyl terminated poly oxyalkylene, an amine curing compound and/or a form of benzene have been disclosed in the prior art. For example, U.S. Pat. No. 4,363,882 to WEGNER discloses a composition that is used as a flame retardant polyurethane foam. This prior art patent does not disclose or teach the particular composition of the present invention.
U.S. Pat. No. 4,772,676 to KOCH et al discloses a polyisocyanate polymer having good flame retardant properties. This prior art patent does not disclose or teach the particular composite material of the present invention.
U.S. Pat. No. 4,939,182 to MARUGG et al discloses a composition that is used for the patching and repairing of rubber tires for vehicles. This prior art patent does not disclose or teach the particular composite material of the present invention.
None of the aforementioned patents disclose or teach the composite material for construction in the manufacture of panels, power transmission poles, conduits, or insulation barriers of the present invention.
Accordingly, it is an object of the present invention to provide a composite material for construction used in the building and construction of personal dwellings/houses, commercial businesses, and industrial facilities, wherein such construction composite products include foundations, building pads, interior wall erecting panels, exterior wall panels, facade facings, roofing panels, mortarless building blocks, conduits, columns, sewage piping, manholes, manhole covers, septic tanks, insulation barriers, fire rated acoustical panels and the like.
Another object of the present invention is to provide a composite material for construction used in the manufacture of power transmission poles, utility poles, overhead lighting poles; sewage facility infrastructure piping, and septic tanks; railroad ties; pallets; spacers; insulation barriers for protecting hulls, bulkheads, overheads, and compartments of ships, aircraft, railway tanker cars, tanker trucks, military vehicles (i.e. tanks) and the like; piers and docks; pylons; dolphins; buoys; and chemical storage tanks.
Another object of the present invention is to provide a composite material for construction that is a bonded composition matrix which includes a unique combination of chemical components having integral support structures (non-chemical) therein for an improved method of manufacture of panels, transmission poles, conduits, piping, insulation barriers and the like.
Another object of the present invention is to provide a composite material for construction used in the building construction of site accessories such as streets, walkways, fencing, outdoor benches and tables, playground equipment (swings, jungle gyms, seesaws and the like); and overhead lighting poles.
Another object of the present invention is to provide a composite material for construction that gives excellent production of custom surfaces, textures and colors in replicating such construction products as wood, brick, cinder block, stone, cement, metal finishes, ceramic tile, stucco, roofing shingles, siding, marble flooring and the like.
Another object of the present invention is to provide a composite material for construction that has a performance index level superior to that of construction materials such as concrete, steel, wood, brick and cinder block for compressive, tensile, flexural and shear strengths.
Another object of the present invention is to provide a composite material for construction that has a compressive strength to weight ratio greater than 95,000 and a R factor greater than 25 (R factor is the measure of the thermal resistance of the material for the passage of heat therethrough (hr-ft
2
-° F./BTU).
Another object of the present invention is to provide a composite material for construction that reduces product manufacturing costs due to more efficient process production methods.
Another object of the present invention is to provide a composite material for construction that will increase product distribution efficiency due to increased trucking capacity in carrying lighter weight components.
Another object of the present invention is to provide a composite material for construction that reduces product weight to below 130 pounds per cubic foot due to new and improved manufacturing methods in order to decrease product shipping costs due to lighter weight components.
Another object of the present invention is to provide a composite material for construction that will increase cash flow due to increased production rates in the manufacturing of the composite material products in using the new and improved manufacturing methods of the present invention.
Another object of the present invention is to provide a composite material for construction that will increase profits through the use of more cost effective products made from the composite material of the present invention.
A still further object of the present invention is to provide a composite material for construction that can be mass produced in an automated and economical manner and is readily affordable by the construction user.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a composition for making a molded construction product, having one or more walls and an inner core section. The composition includes a composition matrix having a resin system, a catalytic agent, and filler compounds for forming walls; a foam core system for forming the inner core section; a curing agent and a drying agent. The resin system is for providing mechanical and physical characteristics of hardness and rigidity to the walls of the molded product, the resin system having a range of 5.00% to 60.0% by weight of the composition. The catalytic agent is for activating the reaction for the polymerization of the resin system, the catalytic agent having a range
Holmes Robert D.
Holmes Valerie L.
McManus Frank J.
Copenheaver Blaine
Holmes Robert D.
Sutton Ezra
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