Construction panel having overlapping edges and foam backing

• US 3,919,443 A
• Filed: 08/17/1973
• Issued: 11/11/1975
• Est. Priority Date: 06/05/1973
• Status: Expired due to Term

• Current Assignee: William H. Porter
• Original Assignee: William H. Porter
• Inventors: Porter, William H.
• Primary Examiner(s): Dier, Philip
• Application Number:
  US05/389,178
• Time in Patent Office: 816 Days
• Field of Search: 161/44,145,111,160 52/586,520,593,309,615,595,753W,578
• US Class Current: 428/81
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2266/0228 Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: E04F 13/18 of organic plastics with or without reinforcements or filling materials of plastic-bound fibres or chips E04F13/16 or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles E04F13/0864 takes precedence
• CPC Class Codes: Y10T 428/24008 including fastener for attaching to external surface
• CPC Class Codes: Y10T 428/249981 Plural void-containing components
• CPC Class Codes: Y10T 428/249985 Composition of adhesive or bonding component specified

Abstract

A prefabricated panel of substantially uniform width and thickness comprising a foamed sheet or slab of a plastic material, and a rigid facing sheet bonded to one surface of the foamed slab, the facing sheet extending beyond the outermost edges of the foamed slab at at least two opposite edges to define flanges, one of the flanges being coplanar with the facing sheet, and the opposite flange being debossed to permit the coplanar flange of an adjacent panel to overlap the debossed flange and to have its outer surface substantially coplanar with the surface of the adjacent panel, the other surface of the foamed slab being exposed for adhesive bonding to the surface of a supporting structure such as an interior wall or ceiling.

Claims

1. A PREFABRICATED PANEL OF SUBSTANTIALLY UNIFORM WIDTH AND THICKNESS, ADAPTED TO BE ADHESIVELY AFFIXED TO A SUPPORTING SURFACE AND TO INTERLOCK WITH AN ADJACENT PANEL OF THE SAME TYPE, COMPRISING A FOAMED SHEET OF A PLASTIC MATERIAL;

A RIGID FACING SHEET BONDED TO THE FOAMED SHEET ON ONE SIDE THEREOF LEAVING ONE SURFACE OF THE FOAMED SHEET EXPOSED;

AN INTEGRAL, SHEET-FORM PLANR FLANGE MEMBER ALONG ONE EDGE OF THE FACING SHEET AND EXTENDING BEYOND THE FOREMOST UNDERLYING EDGE OF THE FOAMED SHEET AND HAVING ITS SURFACES COPLANAR WITH THE SURFACES OF SAID FACING SHEET;

AND AN INTEGRAL, DEBOSSED FLANGE MEMBER ALONG A FACING SHEET EDGE SUBSTANTIALLY PARALLEL TO SAID PLANAR FLANGE MEMBER EXTENDING BEYOND THE FORMOST UNDERLYING EDGE OF THE FOAMED SHEET, THE DEPTH OF DEBOSSMENT OF SAID DEBOSSED FLANGE MEMBER BEING SUFFICIENT TO ACCEPT THE THICKNESS OF SAID COPOLANAR FLANGE, WHEREBY SAID PLANAR FLANGE MEMBER OVERLAPS A DEBOSSED FLANGE MEMBER OF AN ADJACENT PANEL OF THE SAME TYPE AND ENGAGES ONLY THE OUTER SURFACE OF SAID DEBOSSED FLANGE WHEN ADJACENT PANELS ARE INTERLOCKED.

2. A prefabricated panel according to claim 1, wherein the lower surface of the debossed flange is substantially coplanar with the exposed surface of the foamed sheet.

3. A prefabricated panel according to claim 1, having a coplanar flange along two sides of the panel and having a debossed flange along the other two sides of the panel.

4. A prefabricated panel according to claim 1, wherein said foamed sheet is composed of polystyrene.

5. A prefabricated panel according to claim 1, wherein said facing sheet is composed of fiberglass-reinforced polyester resin.

6. In combination, means defining a support surface and a plurality of abutting, interlocked prefabricated panels, each panel comprising a foamed sheet of a plastic material;

a rigid facing sheet bonded to the foamed sheet on one side thereof leaving one surface of said foamed sheet exposed;

an integral, sheet-form planar flange member along one edge of the facing sheet and extending beyond the foremost underlying edge of the foamed sheet and having its surfaces coplanar with the surfaces of said facing sheet; and

an integral, debossed flange member along a facing sheet edge substantially parallel to said planar flange member extending beyond the foremost underlying edge of the foamed sheet, the depth of debossment of said debossed flange member being sufficient to accept the thickness of said coplanar flange, the exposed side of each of said foamed sheets being adhesively affixed to said supporting surface, and the planar flange member of each panel overlapping the debossed flange member of an adjacent panel and engaging only the outer surface of said debossed flange.

7. The combination according to claim 6, wherein the adhesive affixing the surface of each foamed sheet to said supporting surface is a mastic-type adhesive.

8. The combination according to claim 6, wherein said foamed sheet is composed of polystyrene.

9. The combination according to claim 6, wherein said facing sheet is composed of fiberglass-reinforced polyester resin.

10. The combination according to claim 6, wherein said debossed flanges have nails disposed therethrough, the ends of said nails being disposed in said supporting surface, whereby said debossed flanges are additionally affixed to said supporting surface.

11. The combination according to claim 6, wherein an adhesive is provided between each debossed flange and coplanar flange of soft and tacky consistency whereby longitudinal movement between adjacent panels may take place while maintaining said flanges in sealed condition.

12. The combination according to claim 6, wherein the edge of each coplanar flange is spaced apart from the shoulder formed at the proximal edge of the adjacent debossed flange, and a filling material is positioned in the space therebetween having its outer surface coplanar with the surfaces of said coplanar flange and the adjacent panel.