Structural panel with compressible dividers

• US 7,207,151 B2
• Filed: 06/27/2006
• Issued: 04/24/2007
• 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., Kuperus, Ko, Throne, Jason T.
• Primary Examiner(s): CHAPMAN, JEANETTE E
• Application Number:
  US11/475,780
• Publication Number:
  US 20060260271A1
• Time in Patent Office: 301 Days
• Field of Search: 527/831, 527/821, 527/931, 527/931.1, 527/831.9, 527/831.4, 527/831.5, 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 compressible structural panel comprising in combination:

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

a plurality of contiguous or closely adjacent side-by-side compressible dividers of elongated tubular construction formed from individual strips of material,

said dividers being expanded in a resting condition and secured to and protruding from said inner face, and

a connector means for securing said dividers together at locations distal from said outer sheet.

4. The panel of claim 1, 2 or 3 wherein said elongated tubes in cross section define a pair of stacked, inverted truncated triangles.

5. The panel of claim 1 or 2 wherein said strips, further include elongated fold lines.

6. The structural panel of claim 1 or 3 wherein said dividers are of elongated tubular construction having substantially flat upper and lower surfaces, said lower surface being secured to said outer sheet and said upper surface to said connector means.

7. The structural panel of claim 1 or 2 wherein said dividers have a pair of side partitions with each side partition having an inwardly folded fold line.

8. The structural panel of claim 6 wherein said upper surface is smaller than said lower surface.

9. The structural panel of claim 7 wherein each side partition has an upper portion above the fold line and a lower portion beneath the fold line and wherein said upper portion of each side wall is shorter than said lower portion.

10. The structural panel of claim 7 wherein each side partition has an upper portion above the fold line and a lower portion beneath the fold line and wherein said upper and lower portions are substantially the same length.

2. A compressible structural panel comprising in combination:

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

a plurality of compressible dividers of elongated tubular construction formed from individual strips of material, said dividers being expanded in a resting condition and secured to and protruding from said inner face, each divider having a flat upper surface and a flat lower surface, said lower surface being secured to said inner face and being larger than said upper surface, and

connector means for securing said dividers together along their upper surfaces.

11. The panel of claim 2 wherein the lower surfaces of adjacent dividers are secured to said outer sheet in immediately adjacent or contiguous relationship with each other.

12. The panel of claim 2 wherein the lower surfaces of adjacent dividers are secured to said outer sheet in immediately adjacent or contiguous relationship with each other and said upper surfaces are connected to said connector means in spaced relationship from each other.

3. A compressible structural panel comprising in combination:

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

a plurality of compressible dividers of elongated tubular construction formed from individual strips of material, said dividers being expanded in a resting condition and secured to and protruding from said inner face, each divider having a pair of side walls with each side wall having a single longitudinal fold line defining an upper portion and a lower portion and wherein the upper portion is smaller than the lower portion, and

connector means for securing said dividers together at locations distal from said outer sheet.