Method of manufacturing a compressible structural panel with reinforcing dividers

• US 7,194,846 B2
• Filed: 06/27/2006
• Issued: 03/27/2007
• Est. Priority Date: 04/24/2000
• Status: Expired due to Term

• Current Assignee: Certainteed Ceilings Corp (Compagnie De Saint-Gobain S.A.)
• Original Assignee: Hunter Douglas Incorporated (Hunter Douglas N.V.)
• Inventors: Colson, Wendell B., Swiszcz, Paul G., Throne, Jason T., Kuperus, Ko
• Primary Examiner(s): CHAPMAN, JEANETTE E
• Application Number:
  US11/475,781
• Publication Number:
  US 20060260272A1
• Time in Patent Office: 273 Days
• Field of Search: 527/831, 527/821, 527/931, 527/931.1, 527/831.9, 527/831.4, 525/060.1, 525/060.6, 52144-145, 428/77, 428/116, 428/174, 428/178, 428/188, 428/190, 156/200, 156/203, 156/217, 156/222, 156226-227, 160/84.04, 160/84.05, 160/136, 160/166.1
• US Class Current: 52/793.11
• 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 method of manufacturing a structural panel such that it is self expanding from a compressed condition to an expanded substantially incompressible condition, comprising the steps of:

providing an outer sheet of material, providing a plurality of elongated dividers having fold lines therealong such that the dividers can be folded in either direction along said fold lines, said dividers being made of glass fibers that are bonded together with a mixture of thermoset and thermoplastic resin such that the dividers are biased toward a flat condition even after having been folded, and securing the dividers to the outer sheet along one side thereof in closely adjacent relationship such that when the dividers are folded in a first direction along said fold lines the panel can be compressed with the dividers in closely adjacent relationship to said outer sheet and when folded in an opposite direction the dividers abut adjacent dividers to reinforce the dividers rendering the panel substantially incompressible.

2. The method of claim 1 further including the step of increasing the amount of thermoplastic in the mixture to extend the time period in which the dividers move from the compressed condition to the expanded condition.

3. The method of claim 1 or 2 further including the step of securing a connector means to an opposite side of said dividers from said one side where the dividers are connected to the outer sheet to prevent the dividers from expanding to a flat condition.