MAGNESIUM-OXIDE BASED CONSTRUCTION PANEL AND PROCESS FOR MANUFACTURING SAME
A construction panel is formed from a composition comprising one or more of the following ingredients: magnesium oxide, recycled magnesium oxide, fibrous chips, wood chips, bamboo chips, chemical additive and water. A method of manufacturing the construction panel is also disclosed to include mixing magnesium oxide, recycled magnesium oxide, fibrous chips and chemical additive in an aqueous solution to form a semi-arid mixture, and pouring the mixture through a funnel onto a conveyor belt. The conveyor belt passes the mixture through a series of rollers to spread the mixture out evenly in a layer and remove excess liquid. The layer is then cut into panels, which are heat by solar energy before being passing through a spray jet of dried magnesium oxide, and stacked.
1 . A manufactured panel comprising a mixture of:
high purity magnesium oxide;
low purity magnesium oxide;
fibrous chips; and
chemical additive dissolved in an aqueous solution.
2 . The manufactured panel of claim 1 , wherein the high purity magnesium oxide has a purity of at least 79%.
3 . The manufactured panel of claim 1 , wherein the low purity magnesium oxide has a purity of at least 20%.
4 . The manufactured panel of claim 3 , wherein the low purity magnesium oxide mixture further comprises recycled manufactured panels.
5 . The manufactured panel of claim 1 , wherein the fibrous chips are from the group consisting of wood and bamboo chips.
6 . The manufactured panel of claim 1 , wherein the manufactured panel comprises load bearing walls, non-load bearing walls, ceilings, roofing, siding, insulated walls, and tile backer.
7 . A manufactured panel comprising:
at least 5% magnesium oxide;
at least 50% recycled magnesium oxide;
at least 40% fibrous chips; and
at least 5% chemical additive in an aqueous solution.
8 . The manufactured panel of claim 7 , wherein the recycled magnesium oxide material includes recycled manufactured panel material.
9 . The manufactured panel of claim 7 , wherein the fibrous chips are from the group consisting of wood and bamboo chips.
10 . A method of manufacturing a construction panel comprising:
a. preparing a semi-arid mixture of high purity magnesium oxide, low purity magnesium oxide, fibrous chips, and chemical additive in an aqueous solution;
b. pouring said semi-arid mixture through a funnel;
c. dispensing said semi-arid mixture from said funnel onto a conveyor belt;
d. passing the dispensed semi-arid mixture through a roller, where the roller is configured to press and spread said semi-arid mixture against the conveyor belt to a layer of desired uniform thickness;
e. pressing the layer through a compressor, where the compressor is configured to remove excess liquid from said layer; and
f. cutting said compressed layer into panels of predetermined length.
11 . The method of claim 10 , wherein the high purity magnesium oxide has a purity of at least 79%.
12 . The method of claim 10 , wherein the low purity magnesium oxide has a purity of at least 20%.
13 . The method of claim 12 , wherein the low purity magnesium oxide mixture further comprises recycled manufactured panels.
14 . The method of claim 10 , wherein the fibrous chips are from the group consisting of wood and bamboo chips.
15 . The method of claim 10 further comprises drying the panels.
16 . The method of claim 15 further comprising heating the panels to a desired temperature.
17 . The method of claim 16 wherein the panels are heated by solar energy.
18 . The method of claim 10 , further comprising:
passing the panels through a jet, where the jet is configured to spray dry magnesium oxide on the panels; and
stacking the panels.
19 . A system for manufacturing a construction panel comprising:
a. means for preparing a semi-arid mixture of high purity magnesium oxide, low purity magnesium oxide, fibrous chips, and chemical additive in an aqueous solution;
b. means for dispensing said semi-arid mixture onto a conveyor belt;
c. means for spreading said semi-arid mixture against said conveyor belt to a layer of desired uniform thickness;
d. means for removing excess liquid from said layer; and
e. means for cutting said layer into panels of predetermined length.
20 . The system of claim 19 further comprising:
means for drying said panels;
means for spraying dry magnesium oxide onto said panels; and
means for stacking said panels.