Compressible structural panel with fire resistant properties

• US 20060260270A1
• Filed: 06/27/2006
• Published: 11/23/2006
• Est. Priority Date: 04/24/2000
• Status: Abandoned Application

• Current Assignee: Hunter Douglas Incorporated (Hunter Douglas N.V.)
• Original Assignee: Hunter Douglas Incorporated (Hunter Douglas N.V.)
• Inventors: Colson, Wendell B., Swiszcz, Paul G., Kuperus, Ko, Throne, Jason T.
• Application Number:
  US11/475,761
• Publication Number:
  US 20060260270A1
• Time in Patent Office: Days
• US Class Current: 52/783.100
• CPC Class Codes: E04B 2009/0492 with fabrics tensioned on frames
• CPC Class Codes: E04B 9/001 characterised by provisions for heat or sound insulation
• CPC Class Codes: E04B 9/0414 being foldable, curvable or rollable
• CPC Class Codes: E04B 9/0428 having a closed frame around the periphery
• CPC Class Codes: E04B 9/0435 having connection means at the edges
• CPC Class Codes: E04B 9/0442 having a honeycomb core
• CPC Class Codes: E04B 9/045 being laminated
• CPC Class Codes: E04B 9/0457 having closed internal cavities
• CPC Class Codes: E04B 9/26 by means of snap action of elastically deformable elements held against the underside of the supporting construction
• CPC Class Codes: E04C 2/3405 spaced apart by profiled spacer sheets
• CPC Class Codes: Y10T 428/24149 Honeycomb-like
• CPC Class Codes: Y10T 428/24661 Forming, or cooperating to form cells

Abstract

A structural panel for use in building structures or in the formation, finish or decoration thereof includes an outer sheet and a connector sheet with a plurality of collapsible or compressible dividers therebetween. The panel in a rest condition is expanded and of a desired thickness for final use but can be compressed into a relatively thin thickness or profile for shipping purposes. The panel is very lightweight but structurally strong and can be selectively bent in one transverse direction if desired. The panel can be easily cut or formed into any predetermined size or shape.

Claims

1. A compressible structural panel comprising in combination:

at least one outer sheet of material having an inner and outer face, and;

at least one compressible resilient divider that has been creased and folded, is expanded in a resting condition and expands after having been compressed, and is secured to and protrudes from said inner face, said divider being made of a material having fibers embedded in a resin which is both thermosetting and fire resistant.

2. The panel of claim 1 wherein said fibers are glass fibers.

3. The panel with claim 1 wherein said fibers are a blend of glass fibers and polyester fibers.

4. The panel of claim 1 herein said resin is Poly Acrylic Acid (PAA).

5. The panel of claim 1 wherein said resin is Melamine Formaldehyde.

6. The panel of claim 1 wherein said outer sheet is made with fibers embedded in a resin and wherein the resin is fire resistant.

7. The panel of claim 6 wherein said fibers are glass fibers.

8. The panel of claim 6 wherein said fibers are a blend of glass fibers and polyester fibers.

9. The panel of claim 6 wherein said resin is Poly Acrylic Acid (PAA).

10. The panel of claim 6 wherein said resin is Melamine Formaldehyde.

11. The panel of claim 1 or 6 wherein said resin in said outer sheet is a thermosetting resin.

12. The panel of claim 1 or 6 further including connector means for securing said dividers together at locations distal from said outer sheet.

13. The panel of claim 12 wherein said connector means is made of fibers embedded in a resin and wherein said resin is fire resistant.

14. The panel of claim 12 wherein said connector means comprise a plurality of flexible and non-extensible strands interconnecting said dividers.

15. The panel of claim 1 or 6 further including a decorative sheet of material secured to said outer face of said outer sheet, said decorative sheet having a coating of a fire retardant.

16. The panel of claim 15 wherein said fire retardant coating is an acrylic binder.

17. The panel of claim 1 or 6 wherein said fibers in said dividers and outer sheet are in the form of a matrix.

18. The panel with claim 1 or 6 wherein said material for said dividers and outer sheet is substantially 85% by weight 13 micron glass fibers and 15% by weight Poly Acrylic Acid.

19. The panel of claim 18 wherein said material for said dividers and said outer sheet is 120 gsm.

20. The panel of claim 19 wherein said fibers have diameters in the range of 3 to 20 microns.

21. The panel of claim 20 wherein the fibers are approximately the same length.

22. The panel of claim 21 wherein the length of said fibers is approximately 0.75±

0.08 inch.

23. The panel of claim 21 wherein the fibers are shorter than 3 inches.

24. A compressible structural panel comprising in combination:

at least one outer sheet of material having an inner and outer face, said at least one outer sheet being comprised of glass fibers bonded together substantially exclusively with a melamine formaldehyde resin, and

at least one compressible divider that in a resting condition is fully expanded and secured to and protrudes from said inner face.

25. The panel of claim 24 wherein said fibers are nonwoven.

26. The panel of claim 24 or 25 further including a decorative sheet secured to at least one of said at least one outer sheet substantially exclusively with a melamine formaldehyde resin.

27. The panel of claim 24 wherein said at least one divider is secured to said inner face with a resin having no fire resistant qualities.

28. A compressible structural panel comprising in combination:

at least one outer sheet of material having an inner surface and an outer surface, said at least one outer sheet being comprised of glass fibers bonded together substantially exclusively with a fire retardant melamine resin, and

at least one compressible divider that in a resting condition is fully expanded and secured to and protrudes from said inner face.