Self supportive panel system

• US 9,175,476 B2
• Filed: 02/18/2014
• Issued: 11/03/2015
• 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., Peterson, James K., Broad, Robert P.
• Primary Examiner(s): Chapman, Jeanette E
• Application Number:
  US14/182,397
• Publication Number:
  US 20140366474A1
• Time in Patent Office: 623 Days
• Field of Search: 527/821, 527/961, 527/941, 527/991, 527/841, 527/831, 527/841.4, 527/931, 527/461, 523/094, 524/811, 526/531, 428/73, 428116-118
• US Class Current: 1/1
• 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 structure, comprising:

a first structural panel,

a second structural panel joined directly or indirectly to said first structural panel,

wherein at least one of said first or second structural panels includes,

one or more frame members,

a core, having first and second opposing faces,

a first plate attached to said first core face,

a second plate attached to said second core face,

wherein said core includes unifying material,

wherein said first and second structural panels are joined to one another by way of a common wedge member;

wherein said wedge member is fabricated from the same type of material used to fabricate at least one of said first or second structural panels.

2. The structural panel of claim 1, wherein said wedge member has a generally triangular cross-section.

3. The structural panel of claim 1, wherein the unifying material includes a honeycomb shaped material.

4. The structural panel of claim 3, wherein the honeycomb shaped material is fabricated from at least one of stamped steel, plastic, injection molded plastic, fiberglass, cardboard, paper, resin, wood or composite wood based materials.

5. The structural panel of claim 1, wherein the unifying material includes a urethane foam.

6. The structural panel of claim 5, wherein the urethane foam includes an expandable urethane foam.

7. The structural panel of claim 3, wherein the honeycomb shaped material is comprised of hexagonal members having one or more openings for accepting a foam.

8. The structural panel of claim 1, wherein at least one of the first plate, second plate, or the core is adjoined by one or more frame members.

9. The structural panel of claim 8, wherein the one or more frame members encompass at least one peripheral portion of the first plate, second plate or the core.

10. The structural panel of claim 1, wherein at least one of the first or second plate is fabricated from at least one of wood, metal, fiber impregnated resin or plastic.

11. The structural panel of claim 1, wherein the core includes an X-Y grid structure.

12. The structural panel of claim 11, wherein the X-Y grid structure is formed from a woven material.

13. The structural panel of claim 11, wherein the X-Y grid structure is formed from a single unitary member.

14. The structural panel of claim 11, wherein the X-Y grid structure is formed from strands and the strands are mechanically or adhesively joined to one another at one or more points of contact.

15. A roof structure, comprising:

a first structural roof panel,

a second structural roof panel,

and a third, cross-tie panel,

wherein the first and second structural panels are fastened together along respectively associated adjacent edges,

wherein said third, cross-tie panel is connected between said first and second structural roof panels, wherein at least one of said first, second, or third panel includes,

one or more frame members,

a core, having first and second opposing faces,

a first plate attached to said first core face,

a second plate attached to said second core face,

wherein said core includes unifying material,

wherein said first and second structural roof panels are fastened together by way of a wedge member,

wherein said third, cross-tie panel is connected between and connected to at least one of said first and second structural roof panels by way of a wedge member.

16. The structural panel of claim 15, wherein the unifying material includes a honeycomb shaped material.

17. The structural panel of claim 16, wherein the honeycomb shaped material is fabricated from at least one of stamped steel, plastic, injection molded plastic, fiberglass, cardboard, paper, resin, wood or composite wood based materials.

18. The structural panel of claim 15, wherein the unifying material includes an expandable urethane foam.

19. The structural panel of claim 16, wherein the honeycomb shaped material is comprised of one or more hexagonal members having one or more openings for accepting a foam.

20. The structural panel of claim 15, wherein the core includes an X-Y grid structure.