Maximized strength-to-weight ratio panel material

• US 4,351,870 A
• Filed: 10/22/1979
• Issued: 09/28/1982
• Est. Priority Date: 10/22/1979
• Status: Expired due to Term

• Current Assignee: Edgar English Jr
• Original Assignee: Edgar English Jr
• Inventors: English, Edgar Jr.
• Primary Examiner(s): Thibodeau, Paul J.
• Application Number:
  US06/086,748
• Time in Patent Office: 1,072 Days
• Field of Search: 428/314.4, 428/182, 428/184, 428/185, 428/186, 428/310, 428/313, 428/315, 428/920, 428/921, 156/210, 106/18.24, 52/232, 52/309.7, 52/309.6, 52/309.16, 52/795, 52/798, 52/799, 52/800
• US Class Current: 428/174
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 2325/00 Polymers of vinyl-aromatic compounds, e.g. polystyrene
• CPC Class Codes: B32B 2375/00 Polyureas; Polyurethanes
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 3/28 characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04C 2/284 at least one of the materials being insulating
• CPC Class Codes: Y10S 428/921 Fire or flameproofing
• CPC Class Codes: Y10T 428/24157 Filled honeycomb cells [e.g., solid substance in cavities, etc.]
• CPC Class Codes: Y10T 428/24628 Nonplanar uniform thickness material
• CPC Class Codes: Y10T 428/24694 Parallel corrugations
• CPC Class Codes: Y10T 428/24727 with planar component
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249976 Voids specified as closed
• CPC Class Codes: Y10T 428/249987 With nonvoid component of specified composition

Abstract

The invention relates to panelling material which may be of a decorative or structural type, or both, and which has a very large magnitude strength-to-weight ratio and which is ideally suited for and in certain forms is embodied in, pattern-pre-cut multiple panels adapted to be quickly and easily assembled and edge-fastened together to form a desired building structure and which, because of its inherent flexibility, will provide an extremely earthquake-resistant structure, whether in a low-rise, moderately reinforced structure or in a high-rise, extensively reinforced structure in a manner which will allow the entire structure to flex and move as a unit, thereby virtually eliminating all tendency to separation of different structural materials during even extreme earthquake-caused flexing movements of the structure. The panelling material includes combustion-inhibiting or fire-extinguishing material carried adjacent to or in a disseminated relationship therethrough and taking the form of particles which in one form are preferably of a heat-responsive nature adapted to decompose when subjected to the heat of combustion and to produce, as a result of such decomposition, an effectively built-in fire-extinguishing gas, usually a halogen and, in a preferred form, a halogen containing a substantial quantity of bromine and adapted to prevent the maintainance of combustion originating from other adjacent structures or materials or sources or to substantially inhibit same and to virtually completely prevent the self-supporting maintainance of combustion of the panelling material.

Claims

1. A decorative and structural panel having a large magnitude strength-to-weight ratio comprising:

a plurality of laminated panelling material layers firmly bonded together at a plurality of area-spaced, area-disseminated, multi-point interface attachment and junction locations, said plurality of layers of laminated panelling material including at least one convoluted, weight-reducing, strength-increasing, stiffening layer of structural, formed material having a plurality of convolutions extending transversely from a surface plane thereof, said convolutions having outer contact surface portions in contact with corresponding surface portions of a next adjacent layer, at least said convoluted layer being made of a formable thin sheet of high strength material, said laminated panel further including at least one low-density, high specific volume, expanded, compressible, foam filler material layer containing and surrounding a plurality of hollow cells, said foam filler material having a maximized volume-to-weight ratio and carrying a fire extinguishing agent comprising a halogenated compound in particulate form, said halogenated compound being decomposible when subjected to the heat of combustion and adapted to produce, as a result of decomposition, a fire extinguishing gas.

2. An article of manufacture as defined in claim 1, wherein said convoluted, weight-reducing, strength-increasing, stiffening layer of said laminated panelling material layers is made of plastic formed with said plurality of convolutions integral therewith and having a desired directional pattern for imparting desired directional strength-maximizing characteristics to the composite laminated panelling material layers.

3. An article of manufacture as defined in claim, 1, wherein said convoluted, weight-reducing, strength-increasing, stiffening layer of said laminated panelling material layers is made of plastic formed with said plurality of convolutions integral therewith and having a desired multi-directional pattern for imparting desired multi-directional strength-maximizing characteristics to the composite laminated panelling material layers.

4. An article of manufacture as defined in claim, 1, wherein said convoluted, weight-reducing, strength-increasing, stiffening layer of said laminated panelling material layers is made of metal formed with said plurality of convolutions integral therewith and having a desired directional pattern for imparting desired directional strength-maximizing characteristics to the composite laminated panelling material layers.

5. An article of manufacture as defined in claim, 1, wherein said convoluted, weight-reducing, strength-increasing, stiffening layer of said laminated panelling material layers is made of metal formed with said plurality of convolutions integral therewith and having a desired multi-directional pattern for imparting desired multi-directional strength-maximizing characteristics to the composite laminated panelling material layers.

6. An article of manufacture as defined in claim 1, wherein said fire extinguishing agent is carried by said expanded layer of foam filler material in layer means closely adjacent to and in area-coextensive disseminated relationship with respect to said expanded layer of foam filler material.

7. An article of manufacture as defined in claim 1, wherein said fire extinguishing agent is carried by said expanded layer of foam filler material in the region of said bonding together of said layers at said junction locations.

8. An article of manufacture as defined in claim 1, wherein said expanded foam material defines and surrounds said plurality of hollow cells, which are of the interconnected and communicating type, thus providing desired hysteretic loss characteristics in addition to said maximized volume-to-weight ratio characteristic.

9. An article of manufacture as defined in claim 1, wherein said expanded foam material defines and surrounds said plurality of hollow cells, which are of the isolated and non-communicating type, thus providing desired compression characteristics in addition to said maximized volume-to-weight ratio characteristic.

10. An article of manufacture as defined in claim, 1, wherein said bonding together of said layers at said junction locations comprises thermal-induced cohesive bonds between adjacent portions of said plurality of layers of said laminated panelling material.

11. An article of manufacture as defined in claim, 1, wherein said bonding together of said layers at said junction locations comprises solvent-and-pressure-induced cohesive bonds between adjacent portions of said plurality of layers of said laminated panelling material.

12. An article of manufacture as defined in claim, 1, wherein said bonding together of said layers at said junction locations comprises adhesive joining means interpositioned between contacting adjacent portions of said plurality of layers of said laminated panelling material effectively hardened, set, and cured in place to provide a firm bond therebetween.

13. An article of manufacture as defined in claim, 1, wherein said bonding together of said layers at said junction locations comprises a plurality of mechanically fastened bond means firmly and rigidly mechanically fastening together adjacent portions of said plurality of layers of said laminated panelling material.

14. An article of manufacture as defined in claim, 1, wherein said plurality of laminated panelling material layers takes the form of a plurality of precut-to-size individual laminated panelling material layer portions so precut, sized and shaped as to be adapted to define a building structure of a predetermined plan, pattern, and shape.

15. An article of manufacture as defined in claim 14, wherein edge parts of said laminated panelling material layer portions are effectively provided with effective edge-joining mounting and assembling means for mounting a plurality of said laminated panelling material layer portions in such a predetermined relationship with respect to each other, to define such a building structure of a predetermined plan, pattern, and shape and adapted to be mounted, assembled, and placed in said predetermined relationship at a building site or location with substantially no cutting or reshaping of said laminated panelling material layer portions being required to achieve the mounting and assembling of said laminated panelling material layer portions in said predetermined relationship.

16. An article of manufacture as defined in claim 14, wherein said individual panelling material layer portions are provided with a desired type of wall-surface having desired wall-surface characteristics.

17. An article of manufacture as defined in claim, 1, wherein said fire extinguishing agent takes the form of a a halogenated hydrocarbon compound comprising carbon tetrabromide.

18. An article of manufacture as defined in claim, 1, wherein said fire extinguishing agent takes the form of a a halogenated hydrocarbon compound comprising carbon tetraiodide.

19. An article of manufacture as defined in claim, 1, wherein said bonding together of said layers at said junction locations comprises pressure-induced cohesive bonds between adjacent portions of said plurality of layers of said laminated panelling material.