Sustainable composite building materials and related methods of manufacture

Abstract

Sustainable composite materials for interior spaces and related methods of manufacture are provided. In one aspect of the invention, the sustainable composite materials include a load-bearing stud. The load-bearing stud includes a plurality of woven burlap layers impregnated with a magnesium oxide resin. The load-bearing stud is formed by creasing a woven burlap sheet to form multiple foldable panels, wetting the foldable panels with a curable resin, layering the foldable panels to achieve a multi-layered prepreg, pressing the multi-layered prepreg to distribute the resin therethrough, compacting the multi-layered prepreg within a mold cavity having the exterior shape of the load-bearing stud, and curing the multi-layered prepreg, wherein the resin includes a mixture of mono-potassium phosphate and magnesium oxide. The load-bearing stud provides a lightweight, dimensionally stable, and environmentally-friendly composite structure to replace lumber studs and metal studs in building constructions.

1 . A method for forming a load-bearing member, comprising:
 creasing a woven burlap sheet to form a plurality of foldable panels;   wetting the foldable panels with a magnesium oxide resin;   folding the foldable panels to achieve a multi-layered prepreg;   pressing the multi-layered prepreg to distribute the magnesium oxide resin;   compacting the multi-layered prepreg within a mold cavity having the exterior shape of the load-bearing member; and   curing the multi-layered prepreg.   
     
     
         2 . The method according to  claim 1  wherein the curing step is performed at room temperature. 
     
     
         3 . The method according to  claim 1  wherein the resin includes an agitated mixture of magnesium oxide, mono-potassium phosphate and water. 
     
     
         4 . The method according to  claim 3  wherein the resin includes a ratio of mono-potassium phosphate and magnesium oxide between about 3:1 and 1:1 by weight. 
     
     
         5 . A composite building member comprising:
 a plurality of woven burlap layers pre-impregnated with a magnesium oxide resin to form a hardened load-bearing stud when cured at substantially room temperature.   
     
     
         6 . The composite building member of  claim 5  wherein the load-bearing stud includes a generally U-shaped cross-section. 
     
     
         7 . The composite building member of  claim 5  wherein the load-bearing stud includes a generally C-shaped cross-section. 
     
     
         8 . The composite building member of  claim 5  wherein the load-bearing stud includes a base segment and left and right leg segments. 
     
     
         9 . The composite building member of  claim 5  wherein the resin is substantially free of silica. 
     
     
         10 . The composite building member of  claim 5  wherein the resin is substantially free of boric acid. 
     
     
         11 . A modular wall panel assembly comprising:
 a first magnesium oxide wall panel;   a second magnesium oxide wall panel; and   a plurality of studs interposed between the first and second magnesium oxide wall panels, wherein the plurality of studs include a plurality of woven burlap layers pre-impregnated with a magnesium oxide resin.   
     
     
         12 . The modular wall panel assembly of  claim 11  wherein the plurality of studs include:
 an elongate bottom stud; 
 an elongate top stud; and 
 a plurality of vertical studs spanning the height of the first and second wall panels. 
 
     
     
         13 . The modular wall panel assembly of  claim 11  wherein the plurality of studs are bonded to the first and second wall panels with an adhesive. 
     
     
         14 . The modular wall panel assembly of  claim 13  wherein the adhesive includes a hotmelt. 
     
     
         15 . The modular wall panel assembly of  claim 11  wherein the modular wall panel assembly includes embedded wires or cables. 
     
     
         16 . The modular wall panel assembly of  claim 11  wherein at least one of the first and second wall panels includes a digital printing thereon. 
     
     
         17 . The modular wall panel assembly of  claim 11  wherein the wall panels and the load-bearing studs are substantially free of boric acid and silica. 
     
     
         18 . The modular wall panel assembly of  claim 11  wherein the wall panels and the studs are mold resistant and fire resistant.