Self supportive panel system

• US 8,122,681 B2
• Filed: 03/31/2010
• Issued: 02/28/2012
• Est. Priority Date: 03/31/2003
• Status: Expired due to Term

• Current Assignee: PN II Incorporated (Pultegroup Incorporated)
• Original Assignee: PN II Incorporated (Pultegroup Incorporated)
• Inventors: Wrass, Lawrence J., Petersen, James K., Broad, Robert P.
• Primary Examiner(s): Chapman, Jeanette E.
• Application Number:
  US12/751,180
• Publication Number:
  US 20100186310A1
• Time in Patent Office: 699 Days
• Field of Search: 527/841.4, 527/841.5, 523/091.4, 527/931.1, 527/931, 528/23, 528/06, 527/10, 527/07, 527/11, 528/25, 522/93, 528/09, 527/94, 527/82, 527/85, 522/381, 522/39, 527/01, 527/79, 523/091.5, 527/451.9, 527/461, 527/461.1, 524/061, 524/062, 524/063, 524/071, 524/074, 524/15, 52 41- 43, 524/043, 52272-274, 52/911, 52/913, 527/941, 527/821, 522/70, 428116-118, 428/73, 428/192, 156/920, 156/71, 108/51.1, 108/51.901, 108/51.11, 280/781, 280/785
• US Class Current: 52/746.11
• CPC Class Codes: E04B 7/22 the slabs having insulating properties, e.g. laminated with layers of insulating material
• CPC Class Codes: E04C 2/365 by honeycomb structures
• CPC Class Codes: E04C 2/384 with a metal frame
• CPC Class Codes: E04C 2/386 with a frame of unreconstituted or laminated wood
• CPC Class Codes: E04C 2/388 with a frame of other materials, e.g. fibres, plastics
• CPC Class Codes: E04D 1/28 Roofing elements comprising two or more layers, e.g. for insulation
• CPC Class Codes: E04D 1/36 Devices for sealing the spaces or joints between roof-covering elements sealing joints not restricted to roof-covering elements E04B1/68; channels at the intersection of roof surfaces E04D13/0445
• CPC Class Codes: E04D 11/005 Supports for elevated load-supporting roof coverings
• CPC Class Codes: E04D 13/17 Ventilation of roof coverings not otherwise provided for ventilation of rooms or spaces F24F
• CPC Class Codes: E04D 3/32 of plastics, fibrous materials, or asbestos cement
• CPC Class Codes: E04D 3/351 at least one of the layers being composed of insulating material, e.g. fibre or foam material
• CPC Class Codes: E04D 3/357 comprising hollow cavities
• CPC Class Codes: Y10T 428/236 Honeycomb type cells extend perpendicularly to nonthickness layer
• CPC Class Codes: Y10T 428/239 Complete cover or casing
• CPC Class Codes: Y10T 428/24149 Honeycomb-like
• CPC Class Codes: Y10T 428/24157 Filled honeycomb cells [e.g., solid substance in cavities, etc.]
• CPC Class Codes: Y10T 428/24165 Hexagonally shaped cavities
• CPC Class Codes: Y10T 428/24777 Edge feature
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]
• CPC Class Codes: Y10T 442/3423 Plural metallic films or foils or sheets
• CPC Class Codes: Y10T 442/3854 : Woven fabric with a preformed polymeric film or sheet
• CPC Class Codes: Y10T 442/3943 : Plural paper or wood pulp layers

Abstract

A self supporting panel system used to fabricate ceilings, floors, walls, or roofs. The panel system is assembled from a plurality of panels, each having a core that is sandwiched between opposing plate members. In a preferred embodiment, the core of each panel includes a unifying material to enhance the load bearing capacity of the panel.

Claims

1. A method for forming a roof structure, comprising:

providing a plurality of interconnected frame members, the frame members forming an opening;

locating a core having first and second opposing faces within the opening, the core including a plurality of integrally formed honeycomb cells;

filling at least a portion of each of the honeycomb cells with a unifying foam material;

attaching a first plate to the first core face;

attaching a second plate to the second core face;

locating at least one wedge member adjacent the first or second plate;

locating a plurality of rafter boards adjacent one or more of the at least one wedge members so that the rafter boards do not directly contact the first or second plate.

2. The method of claim 1, wherein the honeycomb cells are fabricated from at least one of stamped steel, plastic, injection molded plastic, fiberglass, cardboard, paper, resin, wood, composite wood based materials.

3. The method of claim 1, wherein the unifying foam material includes a urethane foam.

4. The method of claim 3, wherein said urethane foam includes an expandable urethane foam.

5. The method of claim 1, wherein the honeycomb shaped material is comprised of hexagonal members having one or more openings for accepting the foam.

6. The method of claim 1, wherein the plurality of frame members encompass at least one peripheral portion of said first plate, second plate or said core.

7. The method of claim 1, wherein at least one of said first or second plate is fabricated from at least one or wood, metal, fiber impregnated resin or plastic.

8. A method for forming a roof structure, comprising:

providing a first structural panel and a second structural panel joined directly to said first structural panel, wherein the first and second structural panels are formed by;

providing a core including one or more openings and having first and second opposing faces;

locating an expandable foam material into each opening of the core;

locating a first plate attached to said first core face;

locating a second plate attached to said second core face;

locating one or more frame members about a peripheral portion of the core;

locating a plurality of wedge members adjacent each structural panel wherein at least one wedge member is located adjacent both the first and second structural panels;

locating a plurality of rafter boards adjacent one or more of the plurality of wedge members so that the rafter boards do not directly contact the first or second panel.

9. The method of claim 8, wherein the first and second structural panels are joined to one another by way of a common wedge member.

10. The method of claim 9, wherein the wedge member has a generally triangular cross-section.

11. The method of claim 8, wherein the plurality of wedge members are fabricated from the same type of material used to fabricate at least one of said first or second structural panels.

12. A method for forming a roof structure, comprising:

providing a plurality of interconnected frame members, the frame members forming an opening having at least four edges;

locating a core having first and second opposing faces within the opening, the core including a plurality of integrally formed honeycomb cells;

filling at least a portion of each of the honeycomb cells with an expandable foam material;

attaching a first plate to the first core face;

attaching a second plate to the second core face;

expanding the foam material;

locating a plurality of wedge members adjacent each structural panel wherein at least one wedge member is located adjacent both the first and second structural panels;

locating a plurality of rafter boards adjacent one or more of the plurality of wedge members so that the rafter boards do not directly contact the first or second plate.

13. The method of claim 12, wherein the plurality of wedge members have a generally triangular cross-section.

14. The method of claim 12, wherein the plurality of wedge members are fabricated from the same type of material used to fabricate at least one of said first or second structural panels.

15. The method of claim 12, wherein said the honeycomb cells are fabricated from at least one of stamped steel, plastic, injection molded plastic, fiberglass, cardboard, paper, resin, wood, composite wood based materials.

16. The method of claim 12, wherein the honeycomb shaped material is comprised of hexagonal members having one or more openings for accepting the foam.