Engineered Molded Fiberboard Panels and Methods of Making and Using the Same
First Claim
1. A panel, comprising:
- an elongated sheet of molded fiberboard material of corrugated shape having opposite first and second faces and opposite side edges, each face having a plurality of alternating, longitudinally extending ribs and grooves extending along the length of the sheet, the ribs on the first face each having a first peak and the ribs on the second face each having a second peak facing in the opposite direction to the first peaks;
the sheet having at least one slotted portion which has a plurality of spaced slits cut through the ribs of at least one face and terminating short of the opposite face; and
the panel being formed into at least one curve at said one, slotted portion.
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Accused Products
Abstract
A fiberboard panel is formed from at least one corrugated sheet of molded cellulose fiber material having alternating ribs and grooves. Spaced slits are cut through the ribs on one face of the sheet and terminate short of the opposite face so as to form at least one slotted portion of more flexibility which may be bent to form a curve. The corrugated sheet is sandwiched between two flat sheets of the same material to form a composite panel. The corrugated sheet or panel is formed by a wet processing method including successive cold and hot press steps in which a wet mat is pressed between an opposing perforated platen and non-perforated, elastomeric material platen of cross-sectional shape substantially matching the desired panel shape and dimensions.
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Citations
30 Claims
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1. A panel, comprising:
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an elongated sheet of molded fiberboard material of corrugated shape having opposite first and second faces and opposite side edges, each face having a plurality of alternating, longitudinally extending ribs and grooves extending along the length of the sheet, the ribs on the first face each having a first peak and the ribs on the second face each having a second peak facing in the opposite direction to the first peaks; the sheet having at least one slotted portion which has a plurality of spaced slits cut through the ribs of at least one face and terminating short of the opposite face; and the panel being formed into at least one curve at said one, slotted portion. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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18. A construction panel, comprising:
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a first elongated sheet of molded fiberboard material of corrugated shape having opposite first and second faces and opposite side edges, each face having a plurality of alternating, longitudinally extending ribs and grooves extending along the length of the sheet, the ribs on the first face each having a first, flat peak and the ribs on the second face each having a second, flat peak facing in the opposite direction to the first peaks, the opposing first and second flat peaks forming opposing faces of the sheet, each first peak being connected to adjacent second peaks by angled webs forming opposite side faces of ribs; the fiberboard material being formed from a mixture of at least two different cellulose fibers, one of the fibers comprising bovine processed fiber (BPF); and the peaks on each face having a constant center to center spacing in the range from three inches to six inches and the rib height being in the range from 0.75 inches to 3 inches. - View Dependent Claims (19, 20, 21, 22)
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23. A method of molding a fiberboard panel in a corrugated shape, comprising the steps of:
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hydropulping a furnish of cellulose fiber material into a water solution and mixing to separate the fibers into a pulp; pouring the pulp onto an upper surface of a perforated mold screen in a former box, the screen having a corrugated shape of alternating ribs and grooves corresponding to a predetermined panel shape; removing water from the pulp through the mold screen by applying a vacuum to the lower surface of the screen to leave a wet fiber mat on the screen; removing the sides of the box and transferring the mold screen carrying the wet fiber mat longitudinally into a cold press between upper and lower platens of the press; placing the mold screen onto a perforated lower platen of the press which is of shape corresponding to the mold screen shape; moving an upper, non-porous platen of elastomeric material having a shape matching that of the lower platen and mold screen into engagement with an upper surface of the wet fiber mat to close the cold press; pressing the opposing upper and lower platens towards each other to squeeze the wet fiber mat between the platens and squeeze water out of the mat through the openings in the mold screen and lower platen; separating the platens and transferring the mold screen and fiber mat onto a perforated lower platen of a hot press having an upper platen of non-porous elastomeric material substantially identical to the upper elastomeric platen of the cold press, the upper and lower platens of the hot press having a cross-sectional shape similar to that of the upper and lower platens of the cold press; closing the hot platens on the cold-pressed wet mat and applying pressure and heat to the mat to remove additional water by squeezing and vaporization until the mat has reached a desired densification and is substantially moisture free; and separating the hot platens and removing the mold screen and finished panel from the hot press. - View Dependent Claims (24, 25, 26)
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27. A method of forming a fiberboard panel having at least one curve, comprising:
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hydropulping cellulose fibers and water to form a slurry; pouring the slurry over a corrugated form having alternating ribs and grooves corresponding to a predetermined corrugated panel shape; removing water from the slurry to form a mat having a shape corresponding to the form shape; pressing the mat to remove at least some water from the mat; hot pressing the formed mat to remove at least substantially all of the water from the mat, forming a corrugated panel of bonded cellulose material; cutting a series of slits along at least part of the length of the panel to form a slotted panel portion, the slits extending through the ribs on a first face of the panel and terminating short of the peaks of the ribs on an opposite, second face of the panel; and bending the panel at the slotted panel portion to form a curve. - View Dependent Claims (28, 29, 30)
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Specification