IMPROVED CEMENT COMPOSITION AND CONSTRUCTION FOR BUILDING PANELS AND OTHER BUILDING MATERIALS

Abstract: An improved cement composition includes a sufficient amount of diatomaceous earth to provide substantial heat insulation and resistance to decomposition which would otherwise occur at very high temperatures. The cement composition also includes an amount of fibrous material and/or organic (polymer) binder(s) (integrally and impregnated) sufficient to increase the tensile strength, handleability, and machineability of the cement composition. The composition is initially created to include a plurality of fluid pockets as the basis for achieving the features cited. A composite building panel is formed from the cement composition by pouring or placing the cement composition in a 4- to 6-sided preformed box with integral insulating core. The preformed box becomes bound to the poured/placed cement composition and upon curing becomes an integral part of the final panel product. The building panel includes a surface material that has an organic polymer applied to a first side thereof. The cement composition is provided with a sufficient amount of moisture and/or organic polymer to bind with the organic polymer applied to the surface material so that the surface material is substantially integrally formed with the building panel.

Description: Description IMPROVED CEMENT COMPOSITION AND CONSTRUCTION FOR BUILDING PANELS AND OTHER BUILDING MATERIALS Technical Field The present invention is directed toward improved cement compositions and building materials therefor and, more particularly, the present invention is directed toward an improved cement composition with improved properties and a construction for premanufactured, composite panels using the improved cement composition, which improved composite panels exhibit improved strength, weight, and size characteristics. Background of the Invention Cement has been in the past combined with fine and coarse aggregates to create a mass, referred to herein as conventional concrete, which is typically used for high-strength structures such as pavements and building foundations. Typical materials used to make conventional concrete include Portland cement, sand, crushed stone, gravel, crushed cylinders, etc. However, conventional concrete made as discussed above is not flexible or heat insulating enough to be used independently for building structure components (for example, as stand-alone insulating walls), i.e., building materials other than foundations and wall members that require secondary insulating structure. Also, conventional concrete is extremely heavy limiting it yet for use as building structure components. Further, due to its nature, the conventional concrete composition created as described above results in a rough surface having a lamination bonding quality that is erratic and inconsistent. As a result, laminated skin surfaces, such as veneer, phenolic, vinyl, etc., cannot be sufficiently bound to the rough surface of conventional concrete without considerable secondary preparation. However, for any material to be used for building structures such as walls, cabinets, ceilings, etc., it is desirable to be able to firmly and cost-effectively affix to the materials attractive laminated skin surfaces such as those discussed above. Accordingly, in addition to the lack of flexibility, lack of light weight, and lack of insulating properties, conventional concrete is further not adequate for use as building structure components because of the inability to firmly affix laminated skin surfaces to the rough surface of the conventional concrete. Other prior art attempts to create improved cement composition for building materials have combined Portland cement with diatomaceous earth to create a composition referred to herein as diatomaceous earth concrete. Diatomaceous earth concrete is more insulating and lightweight than conventional concrete and, therefore, is more suitable for use as some building structure components than is conventional cement. However, diatomaceous earth concrete is still not sufficiently insulating or lightweight to be used for most building structure components. Further, diatomaceous earth concrete is not sufficiently light weight or flexible to be used for building structure components, especially in connection with making composite panels. Still further, diatomaceous earth concrete, like the conventional concrete discussed above, has a rough surface to which it is difficult to firmly bond attractive, laminated skin surfaces. In addition, diatomaceous earth concrete will decompose at very high temperatures or upon cooling from very high temperatures. Other attempts to create a cement composition suitable for use as building materials and high-temperature (refractory) material components have resulted in a conventional concrete mixture having air pockets spread throughout, referred to herein as cellular cement. The air pockets give the cellular cement increased insulating and refractory properties as compared to that of conventional cement. Further, the air pockets decrease the weight of the cellular cement, as compared to that of conventional cement. However, like diatomaceous earth concrete, cellular concrete is not sufficiently insulating or lightweight for use as most building structure components. Further, cellular cement is not flexible and has a rough surface to which it is difficult to firmly bond laminated skin surfaces. Still further, this material will crack upon cool down from exposure to 1,800°F temperatures. As discussed above, prior art cement compositions are not suited for many building structure components or high-temperature applications. Further, due to the inflexible nature of existing cement compositions, they have proven unsuitable for use in making composite building materials that can be used as building structure components. Accordingly, it is desirable to provide a cement composition that is strong, lightweight, insulating, high-temperature resistant, flexible, and easily prepared to provide a smooth surface to which a laminated skin surface can be firmly bonded. Further, it is desirable to provide a cement composition that is particularly suited for making composite building materials. It is further desirable to provide an improved composite building material and a method for making the same. Still further, it is desirable to create such a cement composition and building materials using the same that are suitable or use as premanufactured materials, as will be discussed below. Recent changes in todays housing industry has lead to an increased desire by builders for using premanufactured, or fabricated, construction components. As example, builders are now able to use premanufactured building panels, cabinetry, doorways, etc. Such components are desirable since they decrease greatly the time and expense involved in constructing new building structures. However, the use of premanufactured building components requires these components to meet the structural specifications necessary for the resulting structure. The structural specifications are typically based on three structural criteria that are of primary interest, i.e., load bearing strength, shear strength, and total weight. Additional structural criteria that may effect the structural specifications are fire resistance, thermal efficiency, acoustical rating, rot and insect resistance, and water resistance. In addition, it is desirable for premanufactured panels to be readily transportable, e.g., lightweight, easily packaged, and easily handled. Premanufactured panels for building construction have in the past had a variety of constructions, the most common of which is a laminated or composite, panel. One such panel includes a core material of foam, or other insulating material, that may in some embodiments have vertical members for adding structural support. The core material is positioned between wood members and the combination fixed together, e.g., nailed, screwed, and/or glued together. These panels suffer from the disadvantages of being combustible as .well as inadequate sound barriers. Further, these panels are subject to rot, decay, and insect attack. Accordingly, panels constructed in this manner are not deemed satisfactory in many modern building applications. In a variation of the above-described building panel, a laminated skin is fixed to the outside of the wood members. In addition to the inadequacies discussed above, these panels suffer from the added disadvantage of being more expensive. In another known construction for building panels, a foam core is positioned between metal members. Decorative material is typically bonded to the outside of the metal members to provide these building panels. These panels are expensive and suffer from the disadvantage of being very sound transmissive. As a result of their sound transmission properties, an inside wall is generally required to provide an acoustical barrier, thereby further increasing the cost of using these panels. Such panels are not generally suitable for load-bearing applications. Still another construction for building panels provides concrete panels that are typically metal reinforced. Due to the limited compositions for concrete previously available, these panels are heavy and inflexible, making them difficult to handle and, therefore, inadequate as premanufactured building panels. These panels also suffer from the disadvantages of being expensive and poor thermal insulators. Still further, such panels also tend to "sweat" and stay damp during certain climatic conditions. For each of the foregoing reasons, prior art concrete panels have proven inadequate for many building construction applications. In addition to the foregoing inadequacies, building panels constructed with prior art concrete compositions result in a rough surface having a lamination bonding quality that is erratic and inconsistent. As a result, laminated skin surfaces, such as veneer, phenolic, vinyl, etc., cannot be sufficiently bound to the rough surface of concrete panels without considerable secondary preparation. It is desirable, however, to be able to firmly and cost effectively affix to the building panels, laminated skin surfaces such as those discussed above. Accordingly, in addition to the lack of flexibility, high weight, and lack of insulating properties, these prior art concrete panels are further disadvantageous because of the inability to firmly affix laminated skin surfaces to the rough surface of the concrete. Accordingly, it is desirable to provide a building panel that is lightweight and strong. It is further desirable to provide such a building panel that is also a good heat and sound insulator. It is further desirable to provide such a building panel that is also resistant to water, fire and rotting. It is also desirable to provide a building panel having all of the foregoing properties, and which is easily handled. Summary of the Invention In a first embodiment of the invention, a cement composition is provided including cement and an amount of diatomaceous earth sufficient to provide substantial heat insulation while not detracting from the strength of the cement composition. The cement composition used has a plurality of air pockets wherein each of the air pockets is constructed of substantially similar size and wherein the plurality of air pockets are substantially evenly distributed throughout the cement composition. In an alternative embodiment of the invention, a method for making structural cement is provided. The method includes the step of impregnating the surface of the structural cement with a material which converts the surface and subsurface of the structural cement to both strengthen the bondability of the surface and provide a smooth surface. In addition to the above, the present invention includes an improved composite building component. The composite building component includes a cement composition layer having cement and a plurality of fluid pockets each being filled with a fluid. The cement composition layer further includes a sufficient amount of binding material to increase the flexibility of the cement composition layer. The composite building component also includes a layer of an insulating material positioned on one surface of the cement composition layer. In an alternative embodiment of the above-described composite building component, the cement composition is used as top and bottom layers. The composite building component layers include cement and a plurality of fluid pockets each filled with a fluid. The top and bottom layers also have a sufficient amount of binding material to increase the flexibility of the layers. The composite building component of this embodiment has the layer of insulating material being positioned intermediate the top and bottom layers. In another embodiment of the above invention, solid panels ranging from 1" to 4" thickness are poured. These panels can be used with or without laminated skin surfaces in applications where the material is exposed, or may be exposed, to very high temperatures in the range of 1,800 degrees F, or greater. In these applications the panels will resist such high temperatures and cool down from such high temperatures without decomposition. The present invention also provides a method for constructing building panels including the step of applying an organic component to a panel surface material and permitting the organic polymer to dry. A filler material is provided wherein the filler material includes a sufficient amount of an organic compound to bond with the organic component on the surface of the panel surface material. The panel surface material is then positioned in contact with the filler material while the filler material is being poured/placed so that the organic polymer of the panel surface material will bond with the organic polymer of the filler material in order that the panel surface material will become a bound integral part of the building panel. A unique point of difference in this invention and common practice within the panel industry is structural and weight adjustable cement compositions are poured into preconstructed 2- to 6-sided box or half box forms in such a manner as to complete panel construction in one step, as the form box or half form box is an integral part of the final panel. In one presently preferred embodiment of the invention, the filler material of building panels constructed in accordance with the method of the subject invention is a cement composition containing fluid pockets wherein each of the fluid pockets is of substantially similar size and wherein the fluid pockets are substantially evenly distributed throughout the cement base. The building panel may also include panel surface material having an organic component applied to a first side thereof wherein the first side of the panel surface material is substantially integrally formed with the cement base by the bonding of organic components. Brief Description of the Drawings Figure 1 is a partial isometric view of a panel constructed in accordance with the subject invention; Figure 2 is a partial exploded view of the panel illustrated in Figure 1; and Figure 3 is a partial isometric view of the panel illustrated in Figures l and 2. Detailed Description of the Invention An improved cement composition is provided for use in making building structure components. Particularly, the cement composition disclosed herein is lightweight, strong, flexible, and insulating enough for use as wall panels, roofs, subfloors, planks, ceiling panels, building bricks, refractory brick, fire core, shingles, and most other building structure components. Further, the cement composition that is the subject of the present invention is made in manner so that its surface is substantially smooth. Accordingly, laminated skin surfaces are readily bonded to the surface of the cement composition of the subject invention. The improved cement composition is created from cellular cement and a sufficient amount of diatomaceous earth to substantially improve the insulating and fire-resistance properties of the composition while not detracting materially from its strength. The cellular cement is created to include a plurality of fluid pockets having substantially the same size and shape, wherein the fluid in the pockets is of a density less than that of the cement used in the composition. By adding the fluid pockets to the composition, the overall density of the composition is decreased and the insulating properties of the composition are enhanced. However, as the density and number of the fluid pockets increases, the strength of the composition decreases. In a presently preferred embodiment of the invention, the cellular cement has about a 200 pound per square inch strength, obtained by including approximately 4,100 pockets per cubic inch, wherein each pocket is approximately 0.06-0.08 inch, in a cement and diatomaceous earth composition resulting in a cement composition having a density of about 10-35 pounds per cubic feet. Those skilled in the art will recognize, however, that the density of the cement composition can be increased or decreased by decreasing or increasing, respectively, the density of the fluid pockets. The cement composition as described above has been found to provide the best insulating properties and consistent strength when the plurality of fluid pockets are of uniform size and shape and are evenly distributed through the cement composition. Although several methods can be used to cellularize cement, bubbles of uniform size and shape that are uniformly distributed are difficult to obtain by most methods. One presently preferred method is to mix the cement composition with a chemical mixture that reacts with the cement composition to provide small bubbles of uniform size and shape that are spread uniformly throughout the composition. One presently preferred chemical mixture is a proprietary product that is commercially available from Celcore, Inc., located in North Royalton, Ohio (referred to herein as "the Celcore component"). The cellular nature of the cement composition of the present invention increases the insulating and fire-resistance properties of the cement while decreasing its weight. The addition of diatomaceous earth further increases the insulating and fire-resistance properties of the cement composition without significantly decreasing the strength of the composition. Optimum characteristics have been obtained using about 3%-15% diatomaceous earth in the cement composition, as will be discussed in more detail below by reference to the several examples. The addition of the diatomaceous earth increases the insulating properties of the composition by a factor of 1.5 to 9 over prior art compositions of similar weight and strength. Further, it has been discovered that with the addition of diatomaceous earth, as discussed above, the cement composition is able to withstand extremely high temperatures for extended periods of time and not crack upon cool down. As an example, cement compositions made in accordance with the above-described method have withstood l,800d°F temperatures for at least 2 hours without decomposition, and not cracked upon cool down. The above-described cement composition is superior to presently available cement compositions for use as building structure components discussed above. Further additives have been shown to further enhance the desirability of the resulting composition for use as building structure components. The bending strength of the composition has been significantly increased by adding to the mixture fibrous material. In addition to the fibrous material, an amount of binder chemical sufficient to hold the fibers firmly in the concrete mix was added. Examples of fibrous material suitable for use to increase the bendability of the resulting composition include: recycled paper fibers, wood fibers, coconut fibers, sugar cane fibers, treated glass, etc. Fibrous materials that are inert to the environment, such as, coconut, sugar cane, and recycled kraft paper fibers, are particularly preferred. In general, the addition of fiber and diatomaceous earth provides wood qualities to the resulting composition to enable the material to be worked in a manner similar to wood, t.e., nailed, sawed, drilled, routed, etc. Wood fiber can be adequately added to the material using paper fiber. In a presently preferred embodiment of the invention, approximately l%-20% of wood fiber is added to the composition to provide suitable wood qualities. As a substitute for the fibrous material, or in addition to the fibrous material, an amount of polymer may be added to the cement composition to increase its flexibility. Generally, a polymer can be added to react with the Portland cement to increase the elasticity of the particles of the cement composition. Further, a polymer can be added which is selected to be non- reactive with the Portland cement particles to increase the elasticity intermediate the particles of the cement. As examples, a non-PVA polymer can be used to react with the cement and a PVA polymer can be used to be non-reactive with the cement particles. Still another additive found to enhance the strength of the subject cement composition and, accordingly, its suitability for use as the building structure components described above is silica. The addition of silica increases the strength of the resulting composition. Preferably, silica fume is used to uniformly add silica to the cement composition. However, those skilled in the art will readily appreciate that the silica can be added to the cement composition in a number of manners. In a presently preferred embodiment of the invention, approximately 3%-10% silica is added to the composition, in a form suitable for cement hardening. In a particularly preferred embodiment of the invention, the above- described cement compositions are treated after curing to provide a smooth surface suitable for being firmly bonded to laminated skin surfaces, such as veneer, phenolic, vinyl, treated papers, etc. In accordance with the method of the present invention, the cured cement composition is impregnating with specialized polymers to a depth selected to provide a sufficiently smooth top surface and subsurface integration to the top surface to provide maximum strength for bonding to laminated skin surfaces. Impregnation may be accomplished by any of several methods known in the art for impregnating materials to predetermined depths. As examples, the impregnation may be accomplished by dipping or spraying at room or elevated temperatures, at atmospheric or elevated pressures and curing by RF exposure, high temperature or long-term curing methods. In one presently preferred embodiment of the invention, the cured composition is impregnated with a specialized polymer to a depth of approximately 1/4 to 1 inch. The cement compositions described above are particularly suited for building structure components such as wall panels, roofs, subfloors, planks, ceiling panels, bricks, and most other building structure components. One presently preferred use of the cement compositions described above is for making structural panels adequate to meet, or exceed, most governmental building code regulations for strength and thermal insulation. Further, the structural panels made with the cement compositions described above is lightweight making use of the materials easier thereby decreasing the cost of the resulting structure. More particularly, the building structure components of the subject invention are made by placing an amount of the above-described cement composition in a mold or box form. An insulating material is then placed in the form and an additional amount of the above-described cement composition is placed on top of the insulating material so that the insulating material is intermediate the cement composition. After curing, the resulting composite structural component is highly thermally insulating (25 "R"), strong, and lightweight. As described above, the composite structural component may be impregnated with a polymer to provide a smooth and bondable outer surface integral with the subsurface for binding laminate finishes. In addition, the panels may be prepared per the above paragraph except without the insulating core placement. ' Such solid panels will not decompose upon exposure to very high temperatures (1,800°F, or greater) or upon cool down from such high temperature exposures. In addition, the panels may be prepared, without the insulating core, using a higher density cement composition and cut into building bricks. Such bricks have been made with density ranging from 30 to 100 pounds per cubic foot with strengths up to 1,200 PSI. A building panel 100 constructed in accordance with the subject invention is illustrated in Figures 1, 2, and 3. The building panel 100 includes first and second skin surfaces 102 and 104 positioned on opposite sides of the panel 100. The skin surfaces 102 and 104 are separated by a top and bottom 112 and 114, respectively, and first and second joining sides 116 and 118. The first and second skin surfaces 102 and 104, the top and bottom 112 and 114, and the first and second joining sides 116 and 118, are fastened together to form a core chamber, as will be described in more detail below. The first and second joining sides 116 and 118 each have a tongue and groove 120 formed therein. The tongue and groove 120 extends from the top 112 to the bottom 114. The first joining side 116 is positioned with its tongue extending toward the second joining side 118 and the second joining side is positioned with its tongue extending away from the first joining side 116 so that the tongue and groove of adjacent building panels will mate with one another. The tongue and grooves 120 are therefore used for connecting a plurality of building panels 100 to construct a structure as is known in the art. It will be appreciated, however, by those skilled in the art that although the present invention is shown and described by reference to a tongue and groove 120, to be used for connecting adjacent building panels 100, other apparatus could be used for this purpose. One connecting structure that may be suitable for use with the subject invention is the connecting structure shown and described in U.S. Patent Nos. 5,012,625 and 5,090,170, entitled "BUILDING ENCLOSURE SYSTEM AND METHOD" and "BUILDING ENCLOSURE SYSTEM", respectively, both issued to Robert L. Propst. Other arrangements for providing the connecting structure provided by the tongue and grooves 120 could be used, as will readily become apparent to those skilled in the art. The building panel 100 also includes a handling system having first and second support rods 106 and 108 that extend from the top 112 to the bottom 114. The support members may be constructed of metal, plastic, or other material suitable for supporting the insulating core during preparation of the building panel. The first and second support rods each have an engagement system including a plurality of female/female connectors 126 fixed to first and second threaded ends 122 and 124 of the first and second support rods 106 and 108. As will be described below, the handling system, including the first and second support rods 106 and 108, is an integral part of the building panel 100. The handling system provides support to the building panel 100 when it is being constructed and, in combination with the engagement system, facilitates handling of the building panel 100 after it is constructed. After the building panel 100 is constructed, one end of the female/female connectors 126 is exposed, as illustrated in Figure 1. Any connector of proper size having male threads can be mated with the female/female connectors of the building panel 100 to enable handling of the building panel. As an example, during construction an eyelet 128 (Figure 3) may be mated with the female/female connectors 126 to enable lifting and positioning of the building panel 100 with construction machinery. After positioning, a bolt 130 may be mated with the female/female connectors 126 to fix a roof structure or other structure to the building panel 100. Although the engagement system of the building panel 100 is shown and described herein by reference to the female/female connectors 126, other apparatus can be combined with the support rods 106 and 108 to enable handling of the building panel 100. Further, although two support rods 106 and 108 are illustrated herein as extending from the top 112 to the bottom 114, those skilled in the art will appreciate that more or less support rods could be used in differing configurations and positions, as part of or independent of the handling system, without departing from the scope and spirit of the subject invention. An insulating core 110 is positioned interior of the core chamber for providing insulation to the building panel 100. During construction, the insulating core 110 is mounted to the first and second support rods 106 and 108 and thereby positioned interior of the core chamber. In a presently preferred embodiment of the invention, the insulating core 110 is positioned substantially centered between the first and second skin surfaces 102 and 104, the top and bottom 112 and 114, and the first and second joining sides 116 and 118. However, in other applications it may be desirable to alter the positioning or construction of the support rods 106 and 108 to vary the positioning of the insulating core 110. The insulating core 110 may be secured to the first and second support rods 106 and 108 by a variety of methods that will readily become apparent to those skilled in the art. As an example, the insulating core 110 may be fabricated on the first and second support members 106 and 108 and the combination positioned in the core chamber as described above. As another alternative, the first and second support members may be placed in the core chamber and the insulating core 110 later secured thereto by suitable means. As an alterative to securing the insulating core 110 to the first and second support rods 106 and 108, the first and second support rods can provide temporary support to the insulating core 110, without being secured thereto, as will be described below. The insulating core 110 may be selected for providing any type of insulation to the building panel 100. As examples, the insulating core 110 may be selected to provide thermal, noise, or other insulation to the building panel 100. Preferably, a lightweight material is selected for the insulating core 110 so that the strength to weight ratio of the building panel 100 can be maximized. The insulating core 110 also includes a plurality of through connectors 132 that extend from the first side 102 to the second side 104 to provide shear connectors to the panel 100, as will be described in more detail below. The top 112 includes a fill hole 134 through which a filler material 134 (Figure 1) is deposited. The filler material is poured into the core chamber through the fill hole 134. The filler material fills the through connectors 132 so that when the cement composition cures, shear connectors are provided in the through connectors 132. The filler material 136 is selected from a material that can be introduced into the core chamber in relatively fluid form to take the form of the core chamber and to fill the through connectors 132. The filler material 136 is further selected to be a material that can be hardened, by curing or otherwise, to provide structural rigidity to the building panel 100. In a presently preferred embodiment of the invention, the filler material 136 is the improved cement composition described hereinabove. It will be apparent, however, to those skilled in the art that other materials could be used for the filler material 136, without departing from the true scope and spirit of the subject invention. The primary consideration in selecting the appropriate filler material is the desired strength to weight ratio to be maintained, in combination with minimum strength and maximum weight specifications. Accordingly, the filler material will be selected to provide predetermined load bearing strength and weight characteristics. In applications where the load bearing strength can be less than that desired for building panels, materials much lighter than the cement composition discussed above may be used for the filler material 136. After the filler material 136 is introduced into the core chamber to take the form of the core chamber, and to fill the through connectors 132 the filler material is cured or dried, by the most appropriate method. The resulting panel will include a plurality of shear connectors that are formed by the fill material in the through-holes 132. The effect of the shear connectors is to substantially increase the shear strength of the building panel 100. Accordingly, in addition to varying the load bearing strength and weight characteristics of the building panel by varying the composition of the filler material, as discussed above, the shear strength of the building panel can be increased and/or decreased by varying the number and positioning of shear connectors, i.e., varying the number and positioning of through-holes in the insulating core 110. Accordingly, the construction for the building panel 100 provides the user with the ability to select load bearing strength, shear strength, and weight, by varying the composition of the filler material and the construction and positioning of the shear connectors. Still further, both the load bearing strength and the shear strength of the building panel 100 may be altered by varying the size and positioning of the insulating core 110. The resulting building panel may be constructed with compressive strengths in excess of about 40,000 pounds per square inch (per ASTM E-72 which calls for worst case eccentric loading) and weight of 3 to 10 pounds per square foot (based on 4' x 8' x 6" panel). Further, the building panel is fire and water proof and impervious to rot and insect damage. Still further, the building panel is a good thermal and acoustical insulator. A typical building panel, constructed with a thickness of 6 inches will exhibit an insulating value in excess of R30. Structural panels made with the cement compositions described above are lightweight, so that it is easier to handle the structural panels, thereby decreasing the cost of the resulting structure. A particular preparation for the composite structural component is a building panel. The building panel is prepared by placing an amount of the above-described cement composition in a mold or box form. An insulating material is then placed in the form and an additional amount of the above-described cement composition is placed on top of the insulating material so that the insulating material is intermediate the cement composition. After curing, the resulting building panel is highly thermally insulating (30+ "R"), strong, and lightweight. The building panel may be impregnated with a polymer to provide a smooth and bondable outer surface integral with the subsurface for binding laminate finishes. In an alternative embodiment of the present invention, the inside of the first and second skin surfaces 102 and 104 are coated with an organic polymer that is dried prior to adding the filler material to the core chamber. The organic polymer is applied while the first and second skin surfaces 102 and 104 are positioned inside the core chamber, however, those skilled in the art will appreciate that the organic polymer may be added to the first and second skin surfaces 102 and 104 prior to positioning them in the core chamber. The organic polymer is typically selected to provide bonding strength between the first and second skin surfaces 102 and 104 and the filler material 136 when the filler material contains compatible bonding agents that react with the coated surfaces of the first and second skin surfaces. Suitable organic polymers for application to the first and second skin surfaces will readily become apparent to those skilled in the art. After the first and second skin surfaces are in position with the organic polymer dried to the surface thereof, the filler material is added to the core chamber and the building panel 100 is placed in a convenient location for the combination to cure. After curing, the first and second skin surfaces become an integral part of the building panel 100, eliminating the need for otherwise fixing a surface material to the panel as with prior art constructions. In another alternative construction for the building panel, a box form is provided with an outside dimension corresponding to the width, height, and thickness of the desired building panel. The box form includes first and second generally planar sides that are spaced from one another by a distance corresponding to the desired thickness of the building panel. Support members, such as first and second support rods 106 and 108 (Figures 1 and 2), are positioned interior of the box form for supporting an insulating core during preparation. The support members are generally oriented horizontally and/or vertically and positioned centrally of the box form. An insulating core is then positioned proximate the support members thereby to be supported in the box form generally centered between the first and second planar sides. A panel surface material, such as for example, a laminate or other known skin surface, is positioned inside the box form proximate the first and second planar sides. The panel surface material may comprise one or more sides of the resulting building panel. In a presently preferred embodiment of the invention, all six surfaces of the building panel are placed in the box form, e.g., first and second skin surfaces 102 and 104, top and bottom 112 and 114, and first and second joining sides 116 and 118, described by reference to Figures 1 and 2, may be placed in the box form. In another presently preferred embodiment of the invention, only two surfaces of the building panel, e.g., first and second skin surfaces 102 and 104, illustrated in Figures 1 and 2, are placed in the box form. It will be apparent to those skilled in the art that any number and selection of surfaces of the building panel may be placed in the box form in accordance with the subject invention. In another alternate embodiment of the above-described building panel, a 4- to 6-sided box form made of magnesium oxide, or similar material, is filled with a filler material with or without cores inserted. This configuration can be used as a fire resistant door or a building panel. The chief feature of this embodiment is that both main side surfaces of the 6-sided box can be customized to replicate any desired surface during the box molding process. This material can look like a brick, natural rock, wood, or smooth surface and it is impervious to very high heat (in excess of 2,000°F). In a further alternate embodiment of the above-described building panel, organic components are added to the cement composition in addition to, or in lieu of, being added to the panel surface material. In addition, the panels may be prepared per the above paragraphs except without the insulating core. Such solid panels will not decompose upon exposure to very high temperatures (1,800°F, or greater) or upon cool down from such high temperature exposures. Still further, the panels may be prepared, without the insulating core, using a higher density cement composition and cut into building bricks. Such bricks have been made with density ranging from 30 to 100 pounds per cubic foot with compressive strengths up to 1,200 PSI. From the foregoing, it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims. EXAMPLES 1. Example No. 1: Approximately 4% diatomaceous earth was added to Portland cement and the composition mixed as is standard in the art. After mixing, a 5 chemical component provided by the Celcore company, Le., the Celcore component referenced above, was added to the mixture to provide a cement composition having approximately 4,100 air pockets per cubic inch, a density of 25 pounds per cubic foot, strength of about 200 PSI, and thermal insulation value of approximately 3 "R" per inch. The resultant product can be heated to 1,800°F and 10 uniquely, then, can be cooled to ambient temperature without cracking or decomposer. 2. Example No. 2: Approximately 4% diatomaceous earth was added to Portland 15 cement and the composition mixed as is standard in the art. After mixing, the Celcore component was added to the mixture to provide a cement composition having approximately 2,000 air pockets per cubic inch, a density of 60 pounds per cubic foot, strength of about 1,000 PSI, and thermal insulation value of approximately 2 "R" per inch. 20 3. Example No.3: Approximately 4% diatomaceous earth, 2% wood fiber, and 5% integral Polymer binder was added to Portland cement and the composition mixed as is standard in the art. After mixing, the Celcore component is added to the 25 mixture to provide a cement composition having approximately 4,100 air pockets per cubic inch, a density of 25 pounds per cubic foot, strength of about 200 PSI, and thermal insulation value of approximately 3 "R" per inch. The resulting • cement composition exhibits more bendability than that described in Example No. 1, above. 30 __ 4. Example No. 4: Approximately 4% diatomaceous earth, 2% wood fiber, and 5% integral Polymer binder was added to Portland cement and the composition mixed as is standard in the art. After mixing, the Celcore component is added to the 35 mixture to provide a cement composition having approximately 4,100 air pockets per cubic inch, a density of 25 pounds per cubic foot, strength of about 200 PSI, and thermal insulation value of approximately 3 "R" per inch. The resulting cement composition was impregnated to a depth of 1/2" via a dipping method to provide a smooth top surface strongly integrated with the subsurface to maximize the surface strength for bonding to laminated surface materials. 5. Example No. 5: Approximately 4% diatomaceous earth, 1% wood fiber in the form of digested/slurried recycled kraft paper, and 3% integral non-PVA Polymer binder and 3% PVA interstitial binder-filler was added to Portland cement and the composition mixed as is standard in the art. After mixing, the Celcore component is added to the mixture to provide a cement composition having approximately 4,100 fluid pockets per cubic inch, a density of 25 pounds per cubic foot, strength of about 200 PSI, and thermal insulation value of approximately 3 "R" per inch. The resulting cement composition was impregnated with a specialized polymer to a depth of 1/2" via a dipping method. This cement composition is uniquely handleable with minimal breakage and especially suited for cladding to produce composite panels. 6. Example No. 6: The material produced as in Example No. 5, above, was used to construct a 6" thick composite panel where 1" of material prior to impregnation was placed in the bottom of a box form, followed by the placement of a 4" high insulation material (polyisocyanurate) core, followed by placement of an additional 1" of material. Upon curing, the panel was impregnated with specialized polymer to a depth of 1/2", followed by the placement of a glue line and laminate skin (HDO, resin-treated paper, wood, or synthetic material), which was applied in a pressure press machine. The resulting panel features are thermal insulation value of 25 "R", or greater, with a weight under 200 pounds in the 4' x 8' x 6" size. Additionally, the panel has sufficient strength to serve as a single member bearing wall for residential construction. The product is fire- and rot- resistant. 7. Example No. 7: Approximately 10% diatomaceous earth, 2% non-PVA polymer, Portland cement, and Celcore component are mixed to produce a final product composition having approximately 4,100 air pockets per cubic inch and a density of 25 pounds per cubic foot. Two-inch thick panels made from this composition will not decompose when exposed to 1,800°F temperature and will not decompose upon cool down from such high-temperature exposure.

Claims: Claims 1. A cement composition comprised of cement having a plurality of fluid pockets wherein each of said plurality of fluid pockets is of substantially similar size and wherein the plurality of fluid pockets are substantially evenly distributed throughout said cement, said cement composition, having a density of approximately 15 to 100 pounds per cubic foot, said structural cement further including l%-30% diatomaceous earth, 0.5%- 15% wood fiber, 1%-15% specialized chemical binders for inter-cement particle elasticity, with or without 3%-7% hardening silica. 2. Structural building materials comprised of: a cement base having a plurality of fluid pockets wherein each of said plurality of fluid pockets is of substantially similar size and wherein the plurality of air pockets are substantially evenly distributed throughout said cement; and having a top surface integrated with the subsurface to a depth of 1/4" to 1", creating a strongly grounded and smooth top surface created by impregnating said cement base with a specialized polymer. 3. The structural building materials as recited in claim 2 wherein said cement base further includes 0.5%- 15% wood fiber, l%-9% organic chemical filler/binder, with or without 3%-7% hardeners, with or without 1%-15% specialized chemical binders for inter-cement particle elasticity. 4. The structural building materials as recited in claim 3 wherein said cement base further includes 0.5%-15% wood fiber, with or without l%-9% organic chemical filler/binder, with or without 3%-7% hardeners, with or without 1%- 15%. specialized chemical binders for inter-cement particle elasticity. 5. A cement composition comprising cement and an amount of diatomaceous earth sufficient to provide substantial heat insulation and thermal resistance while not detracting materially from the strength of said cement composition, said cement composition further having a plurality of fluid pockets wherein each of said plurality of fluid pockets is of substantially similar size and wherein the plurality of fluid pockets are substantially evenly distributed throughout said cement, said plurality of fluid pockets being substantially filled with a fluid having a density less than the density of said cement. 6. The cement composition as recited in claim 4 wherein said plurality of fluid pockets is substantially filled with air. 7. The cement composition as recited in claim 4 comprised of 1%- 30% diatomaceous earth. 8. The cement composition as recited in claim 4, further including an amount of fibrous material sufficient to increase the tensile strength and wood product characteristics of the cement composition. 9. The cement composition as recited in claim 6 wherein said fibrous material comprises wood fiber. 10. The cement composition as recited in claim 6 wherein said fibrous material comprises treated glass fiber. 11. The cement composition as recited in claim 6 comprising 0.5%- 15% fibrous material. 12. The cement composition as recited in claim 6, further comprising an amount of a binding substance sufficient to hold the fibrous substance firmly in the concrete matrix. 13. The cement composition as recited in claim 10 wherein said binding substance comprises 1%-15% specialized binding substances to increase bendability. 14. A method for making structural cement comprising the step of impregnating the surface of the structural cement with a material sufficient to convert the surface of the structural cement to a substantially smooth top surface which is strongly bound and integrated to the subsurface to a depth of 1/4" to 1". 15. The method as recited in claim 14, further comprising the steps of: providing first and second layers of the structural cement, said first and second layers including cement and a plurality of fluid pockets, said plurality of fluid pockets being substantially filled with a fluid, said first and second layers further including a sufficient amount of binding material to increase the flexibility of said structural cement; and positioning an insulating layer so that said insulating layer is intermediate said first and second layers. 16. The method as recited in claim 14, further comprising the step of adding a material to said first layer, said material selected to be non-reactive with the cement of said first layer to increase the flexibility of said first layer. 17. The method as recited in claim 15, further comprising the step of adding a material to said first and second layers selected to react with the cement of said first and second layers to increase the flexibility of said first and second layers. 18. The method as recited in claim 15, further comprising the step of adding a material to said first and second layers, said material selected to be non- reactive with the cement particles of said first and second layers to increase the flexibility of said first and second layers. 19. A method for constructing building panels comprising the steps of: providing a box form having first and second opposing planar sides joined by edge members to define an interior chamber intermediate said first and second opposing planar sides, said interior chamber having a size corresponding to the desired size of the building panels; positioning support members interior of said interior chamber substantially centered between said first and second planar sides; securing an insulating material to said support members so that said insulating material is supported within said interior chamber substantially centered between said first and second planar sides; positioning panel surface material interior of said interior chamber substantially proximate said first planar side; applying an organic polymer to said panel surface material and permitting the organic polymer to dry; providing a cement composition including cement and a plurality of fluid pockets, said plurality of fluid pockets being substantially filled with a fluid, said cement composition further including a sufficient amount of binding material to increase the flexibility of said cement composition, said cement composition also including a sufficient amount of an organic polymer to bond with the organic polymer on the surface of said panel surface material; and pouring said cement composition into said box form with said panel surface material having the organic polymer dried thereon and with said insulating material positioned therein and permitting said cement composition to cure so that the resulting building panel has as a substantially bound, integral part thereof, said panel surface material. 20. The method as recited in claim 19, further comprising the step of adding a material to said cement composition to react therewith and thereby increase the flexibility of said first layer. 21. The method as recited in claim 19, further comprising the step of adding a material to said cement composition, said material selected to be non- reactive with said cement composition to increase the flexibility thereof. 22. A method for constructing building panels comprising the steps of: applying an organic polymer to a panel surface material and permitting the organic polymer to dry; providing a filler material wherein the filler material is initially in a substantially fluid form and wherein the filler material is constructed to harden into a substantially solid form, the filler material including a sufficient amount of an organic polymer to bond with the organic polymer on the surface of the panel surface material; positioning the panel surface material in contact with the filler material while the filler material is curing so that the organic polymer of the panel surface material will bond with the organic polymer of the filler material and so that the panel surface material will be a substantially bound, integral part of the building panel. 23. The method as recited in claim 19, further comprising the step of positioning an insulating material proximate the panel surface material so that, after the filler material has hardened into a substantially solid material, the insulating material will be positioned substantially interior of the hardened filler material. 24. The method as recited in claim 23, further comprising the substeps of: providing a box form having first and second opposing sides joined by edge members to define an interior chamber intermediate the first and second opposing sides, the interior chamber of size corresponding to the desired size of the building panels; positioning support members inside the interior chamber substantially centered between the first and second sides; securing the insulating material to the support members so that the insulating material is supported within the interior chamber substantially centered between the first and second sides; positioning the panel surface material inside the interior chamber substantially proximate the first side; pouring the filler material into the box form with the panel surface material having the organic polymer dried thereon and with the insulating material positioned therein. 25. The method as recited in claim 22, further comprising the step of providing as the filler material a cement composition with a plurality of fluid pockets, said plurality of fluid pockets being substantially filled with a fluid. 26. The method as recited in claim 25, further comprising the step of providing the plurality of fluid pockets so that the plurality of fluid pockets are substantially evenly distributed throughout the cement composition. 27. Structural building materials comprised of: a cement base having a plurality of fluid pockets wherein each of said plurality of fluid pockets is of substantially similar size and wherein the plurality of fluid pockets are substantially evenly distributed throughout said cement base, said cement base further including an organic polymer; and panel surface material having an organic polymer applied to a first side thereof, the first side of the panel surface material being substantially integrally formed with the cement base by the bonding of the organic polymers. 28. The structural building materials as recited in claim 27 wherein said cement base further includes 0.5%-15% wood fiber, l%-9% organic chemical filler/binder, with or without 3%-7% hardeners, with or without 1%-15% specialized chemical binders for inter-cement particle elasticity. 29. The structural building materials as recited in claim 28 wherein said cement base further includes 0.5%-15% wood fiber, with or without l%-9% organic chemical filler/binder, with or without 3%-7% hardeners, with or without 1%- 15% specialized chemical binders for inter-cement particle elasticity. 30. Structural building material comprised of: a panel surface material having an organic polymer applied to a first surface thereof; and a filler material including a sufficient amount of an organic polymer so that said filler material and said panel surface material are substantially integrally bonded. 31. The structural building material as recited in claim 30 wherein said filler material comprises a cement base having a plurality of fluid pockets wherein each of said plurality of fluid pockets is of substantially similar size and wherein the plurality of fluid pockets are substantially evenly distributed throughout said cement base. 32. The structural building material as recited in claim 30 wherein the structural building material includes an exterior surface, said structural building material further including: a support member positioned interior of said filler material and extending to the exterior surface thereof, said support member including fastening means for permitting said support member to be engaged to thereby physically position said structural building material. 33. The structural building material as recited in claim 30, further including insulating core means positioned interior of said filler material for improving the insulating properties of said structural building material. 34. The structural building material as recited in claim 33 wherein said insulating core means includes a first side remote from said panel surface material and a second side proximate said panel surface material relative to said first side, said insulating core means further including a through-hole extending from said first side to said second side with said filler material positioned in said through-hole. 35. A building panel comprising: first and second surfaces each having an exposed side and a bonded side, said first and second surfaces further having an organic polymer applied to the second sides thereof; a top and bottom positioned substantially intermediate the first and second surfaces at opposite ends thereof, said top having a through connector formed therein; first and second support rods positioned intermediate said first and second surfaces and extending from said top to said bottom, said first and second support members each having first and second threaded ends and having a female/female connector secured to each of the first and second threaded ends; first and second joining sides positioned intermediate said first and second surfaces and extending from said top to said bottom to define a core chamber of said building panel, said first and second joining sides each having a tongue and groove formed therein, said tongue and groove extending from said top to said bottom, said first joining side being positioned with said tongue extending toward said second joining side and said second joining side being positioned with said tongue extending away from said first joining said so that the tongue and groove of adjacent building panels will mate; an insulating core positioned within said core chamber substantially proximate said first and second support rods, said insulating core being provided for improving the insulating characteristics of said building panel, said insulating core including a plurality of through connectors extending laterally through said insulating core in a direction from said first surface toward said second surface; and a cured cement composition positioned within said core chamber, substantially surrounding said first and second support rods and said insulating core, said cured cement composition being further positioned within said through connectors of said insulating core to form shear connectors for improving the shear strength of said building panel, said cured cement composition including cement and a plurality of fluid pockets, said plurality of fluid pockets being substantially filled with a fluid, said cured cement composition further including an organic polymer and being thereby substantially integrally bond with said first and second surfaces.

Inventors: RECORD GRANT C, RECORD, GRANT, C.
Applicants: RECORD GRANT C, RECORD, GRANT, C.
Application year: 1993
Main classification: C04B28
IPC codes: C04B28, E04C2