Compressible structural panel

• US 7,377,084 B2
• Filed: 12/03/2002
• Issued: 05/27/2008
• Est. Priority Date: 04/24/2000
• Status: Expired due to Term

• Current Assignee: CertainTeed Corp. (Compagnie de Saint-Gobain SA)
• Original Assignee: Hunter Douglas Incorporated (Hunter Douglas N.V.)
• Inventors: Kuperus, Ko, Throne, Jason T., Colson, Wendell B., Swiszcz, Paul G.
• Primary Examiner(s): Chapman; Jeanette E.
• Application Number:
  US10/309,939
• Publication Number:
  US 20030154679A1
• Time in Patent Office: 2,002 Days
• Field of Search: 527/831, 527/931, 527/931.1, 527/831.9, 527/831.4, 527/831.5, 527/821, 525/060.1, 52144-145, 525/060.6, 428/116, 428/174, 428/178, 428/77, 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, and a plurality of independent resilient and compressible dividers that in a resting condition are fully expanded and secured to and protrude from said inner face, said dividers being made from strips of material having fibers embedded in resin which strips have been creased without using heat and without damaging many, if any, of the fibers so that a spring force is retained in the strips which are folded to form the dividers, said material further being inherently capable of moving said dividers from a fully compressed to said fully expanded rest condition, said panel further including connector means for securing said dividers together at locations distal from said outer sheet, and wherein said dividers are made from independent sheets of semi-rigid but foldable material, said independent sheets being folded so as to define flaps that are securable to said outer sheet and said connector means and a pair of partitions extending between said flaps, said partitions being collapsible.

2. The panel of claim 1 wherein said partitions are substantially elongated as well as planar and said dividers have a longitudinally extending fold between said flaps and said partitions which allow the partitions to be folded into substantially face-to-face relationship with said flaps when in the compressed condition.

3. The panel of claim 1 wherein said independent sheets are made of fiberglass including a plurality of glass fibers bonded together with a resin.

4. The panel of claim 3 wherein said resin is a thermoset resin.

5. The panel of claim 3 wherein said resin is thermoplastic.

6. The panel of claim 3 wherein said resin is a combination of a thermoset and a thermoplastic resin.

7. The panel of claim 3 wherein said resin is a Poly Acrylic Acid.

8. The panel of claim 3 wherein said outer sheet is fiberglass including a plurality of glass fibers bonded together with resin.

9. The panel of claim 8 wherein said resin in the outer sheet is a combination of thermoset and thermoplastic resin.

10. The panel of claim 8 wherein said resin in the puter sheet is a thermoset resin.

11. The panel of claim 8 wherein said resin in the outer sheet is a thermoplastic resin.

12. The panel of claim 8 wherein said resin in the outer sheet is Poly Acrylic Acid.

13. The panel of claim 8 wherein said connector means is a sheet of material.

14. The panel of claim 13 wherein said connector means is a fiberglass sheet.

15. The panel of claim 13 wherein said connector means includes a plurality of glass fibers bonded together with resin.

16. The panel of claim 15 wherein said resin in the connector means is a thermoset resin.

17. The panel of claim 15 wherein said resin in the connector means is a thermoplastic resin.

18. The panel of claim 15 wherein said resin in the connector means is a combination of thermoset and thermoplastic resins.

19. The panel of claim 15 wherein said resin in the connector means is a Poly Acrylic Acid.

20. The panel of claim 2 wherein said partitions are of the same size.

21. The panel of claim 2 wherein said partitions are of different sizes.

22. The panel of claim 13 wherein said sheet of material consists of a plurality of strips of material.

23. The panle of claim 13 wherein said outer sheet consists of a plurality of strips of material.

24. A compressible structural panel comprising in combination:

at least one outer sheet of material having an inner and outer face, and a plurality of independent resilient and compressible dividers that in a resting condition are fully expanded and secured to and protrude from said inner face, said dividers being made from strips of material having fibers embedded in resin which strips have been creased without using heat and without damaging many, if any, of the fibers so that a spring force is retained in the strips which are folded to form the dividers, said material further being inherently capable of moving said dividers from a fully compressed to said fully expanded rest condition, said panel further including connector means for securing said dividers together at locations distal from said outer sheet and wherein said connector means include a plurality of flexible but not extensible strands interconnecting said dividers.

25. A compressible structural panel comprising in combination:

at least one outer sheet of material having an inner and outer face, a plurality of independent resilient and compressible dividers that in a resting condition are fully expanded and secured to and protrude from said inner face, and connector means for securing said dividers together at locations distal from said outer sheet, said dividers being made from strips of material having fibers embedded in resin which strips have been creased without using heat and without damaging many, if any, of the fibers so that a spring force is retained in the strips which are folded to form the dividers, said material further being inherently capable of moving said dividers from a fully-compressed to said fully expanded rest condition.

26. The panel of claim 25 wherein said dividers are elongated and extend in parallel relationship to each other.

27. The panel of claim 25 wherein said dividers are made of a semi-rigid material.

28. The panel of claim 27 wherein said dividers are foldable as they are compressed into a compressed condition.

29. The panel of claim 25 further including a decorative sheet secured to the outer face of said outer sheet.

30. The panel of claim 25 wherein said dividers are positioned in closely adjacent or contiguous side-by-side relationship.