Self supportive panel system

• US 8,661,770 B2
• Filed: 02/22/2012
• Issued: 03/04/2014
• Est. Priority Date: 03/31/2003
• Status: Active Grant

• Current Assignee: PN II Incorporated (Pultegroup Incorporated)
• Original Assignee: PN II Incorporated (Pultegroup Incorporated)
• Inventors: Wrass, Lawrence J., Broad, Robert P., Petersen, James K.
• Primary Examiner(s): Chapman, Jeanette E.
• Application Number:
  US13/402,067
• Publication Number:
  US 20130029156A1
• Time in Patent Office: 741 Days
• Field of Search: 527/931, 523/091.5, 527/941, 525/921, 525/924, 527/841.4, 527/841.5, 523/091.4, 527/931.1, 522/70, 52 41- 43, 527/821, 522/381, 527/451.9, 527/461, 524/061, 524/062, 52272-274, 52/911, 52/913, 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: 52/784.14
• 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 roof system, comprising:

a plurality of structural panels, each panel including;

a core comprising a plurality of hexagonal members that define a honeycomb structure, the hexagonal members each;

i. having first and second opposing faces;

ii. including a polyurethane foam located within;

iii. including an opening passing completely through the member;

a first plate having a width of about 8 feet attached to said first core face;

a second plate having a width of about 8 feet attached to said second core face;

a peripheral frame surrounding the structural panel;

a plurality of rafter boards, the rafter boards being free of any direct attachment to the structural panels, but being indirectly attached to the structural panels by way of one or more wedge members.

2. The roof system of claim 1, wherein plurality of hexagonal members are fabricated from steel.

3. The roof system of claim 1, wherein plurality of hexagonal members are fabricated from composite materials.

4. The roof system of claim 1, wherein the polyurethane foam is an expandable polyurethane foam.

5. The roof system of claim 1, wherein each wedge member is triangular in shape.

6. The roof system of claim 1, wherein a finish plate is located over an exposed end of each wedge member.

7. The roof system of claim 1, wherein each wedge member includes a hollow core.

8. The roof system of claim 7, wherein the hollow core is filled with a unifying material.

10. The roof system of claim 1, including a first and second structural panel.

11. The roof system of claim 1, wherein the first and second structural panel contact one another along a first panel edge.

12. The roof system of claim 11, wherein the first and second structural panel each contact the plurality of rafter boards indirectly along a second panel edge.

13. The roof system of claim 1, wherein the system is self-supportive and free of any truss structure.

14. The roof system of claim 1, whereby the structural pan allow for spans of at least about 26 feet with no load bearing wall.

15. The roof system of claim 10, wherein the first and second structural panel are attached to one another by an adhesive.

16. The roof system of claim 15, wherein the adhesive is a double sided tape.

17. The roof system of claim 1, wherein the structural panels are attached to the wedge members by an adhesive.

18. The roof system of claim 1, wherein each structural panel includes a fiberglass material located on a surface of each panel.

19. The roof system of claim 1, wherein the first and second plates are located onto each structural panel after filling each hexagonal member with the polyurethane foam.

20. The roof system of claim 4, wherein the first and second plates are located onto each structural panel prior to expansion of the polyurethane foam.

9. The roof system of 8, wherein the unifying material is a foam.