CA2049827A1 - Fiber core materials used for board - Google Patents
Fiber core materials used for boardInfo
- Publication number
- CA2049827A1 CA2049827A1 CA002049827A CA2049827A CA2049827A1 CA 2049827 A1 CA2049827 A1 CA 2049827A1 CA 002049827 A CA002049827 A CA 002049827A CA 2049827 A CA2049827 A CA 2049827A CA 2049827 A1 CA2049827 A1 CA 2049827A1
- Authority
- CA
- Canada
- Prior art keywords
- board
- configurated
- flat wall
- projection
- rows
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000011162 core material Substances 0.000 title description 6
- 239000000835 fiber Substances 0.000 title description 6
- 239000012784 inorganic fiber Substances 0.000 claims abstract description 18
- 239000000463 material Substances 0.000 claims description 37
- 238000003825 pressing Methods 0.000 claims description 8
- 239000000853 adhesive Substances 0.000 claims description 6
- 230000001070 adhesive effect Effects 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 239000003365 glass fiber Substances 0.000 claims description 3
- 238000005259 measurement Methods 0.000 claims description 3
- 239000011490 mineral wool Substances 0.000 claims description 3
- 239000011120 plywood Substances 0.000 claims description 2
- 238000009413 insulation Methods 0.000 description 12
- 238000005452 bending Methods 0.000 description 8
- 239000011491 glass wool Substances 0.000 description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- 229910052782 aluminium Inorganic materials 0.000 description 4
- 239000003292 glue Substances 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 2
- 239000004035 construction material Substances 0.000 description 2
- 230000009970 fire resistant effect Effects 0.000 description 2
- 238000005192 partition Methods 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 239000013598 vector Substances 0.000 description 2
- 241000905957 Channa melasoma Species 0.000 description 1
- 101100285518 Drosophila melanogaster how gene Proteins 0.000 description 1
- 241000845077 Iare Species 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 238000009435 building construction Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 239000005401 pressed glass Substances 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/88—Insulating elements for both heat and sound
Landscapes
- Physics & Mathematics (AREA)
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Acoustics & Sound (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Building Environments (AREA)
- Veneer Processing And Manufacture Of Plywood (AREA)
- Laminated Bodies (AREA)
- Soundproofing, Sound Blocking, And Sound Damping (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
A configurated board is constructed to be positioned between and to be adhered to two outer, flat wall components to provide an integrated structural and/or insulating panel structure. The configurated board is formed of inorganic fiber strands which are heat pressed and adhesively adhered together in a configurated pattern. The configurated board has a wavy curvature in which, on each side of the board, rows of regularly spaced hemispherically shaped depressions alternate side by side with rows of regularly spaced hemispherically shaped projections.
Each projection in a row has four related depressions, in the two adjacent rows, which are closely adjacent to and which are equally spaced from the projection. Each depression in a row on one side of the board corresponds in location to a related projection in the same row on the other side of the configurated board. The top, rounded surfaces of all of the hemispherically shaped projections on a same side of the configurated board are disposed substantially in one plane so as to be readily engagable with and attachable to a related, facing surface of a flat wall component, when the configurated board is mounted and attached as an internal component between two flat wall components, to provide an integrated, structural and/or insulating panel structure.
A configurated board is constructed to be positioned between and to be adhered to two outer, flat wall components to provide an integrated structural and/or insulating panel structure. The configurated board is formed of inorganic fiber strands which are heat pressed and adhesively adhered together in a configurated pattern. The configurated board has a wavy curvature in which, on each side of the board, rows of regularly spaced hemispherically shaped depressions alternate side by side with rows of regularly spaced hemispherically shaped projections.
Each projection in a row has four related depressions, in the two adjacent rows, which are closely adjacent to and which are equally spaced from the projection. Each depression in a row on one side of the board corresponds in location to a related projection in the same row on the other side of the configurated board. The top, rounded surfaces of all of the hemispherically shaped projections on a same side of the configurated board are disposed substantially in one plane so as to be readily engagable with and attachable to a related, facing surface of a flat wall component, when the configurated board is mounted and attached as an internal component between two flat wall components, to provide an integrated, structural and/or insulating panel structure.
Description
'7 FIBER CO~ MATERIALS USED FOR BOARD
BACKGROUND OF THE INVEN~ION
This invention relates to a conEigurated board which is constructed to be positioned between and adhered to two outer, flat wall components to provide an integrated structural and/or insulating panel structure.
This invention relates particularly to a configurated board formed of inorganic fiber component strands which are heat -~
pressed and adhesively adhered together in a wavy curvature in which rows of hemispherical~y shaped depressions alternate with rows of hemispherically shaped projections.
This invention has particular application to structural and insulating panels which need to have a high degree of ~ire reslstance.
Panel structures used in the con6truction industry as indoor construction materials may be used as partitions, doors, ceiling panels, wall panels, and floor panels. Such panels, particularly in apartment complexes and condominium complexes, may need to be constructed so as to reduce noise and to insulate between apartment or condo units.
If is often nece~sary that such panel structures have a relatively high degree of fire resistance.
To achieve a certain level of fire resistance, some such panels have included paper honeycomb as a core between sections ~;
of plywoQd or other flat outer panel materials. The honeycomb paper had to be treated to insure fire resistance.
Other such panels have included the u~e of aluminum or steel : ,, . . : ., . , ~
: ' ;' .. , '~ ' ::
~ "., - ~ :
::
.
as a core.
Glass wool has also been used as a core, primarily for insulation and noise reduction.
The uses of chemically treated paper, aluminum, steel or glass wool as a core for such panel structures have presented certain problems. These problems have included high cost and complexity of manufacturing procedures.
It is a primary ob~ect of the present invention to construct a configurated board which can be used as an internal component in an integrated structural and~or insulating panel stru~ture and which overcomes the problems presented by core materials previously llsed.
It is a related object to form a configurated board of inorganic fiber strands heat pressed and adhesively adhered together into a wavy curvature -- a curvature in which, on each ~
side of the board, rows of hemispherically shaped depressions ' alternate with rows of hemispherically shaped projections.
It is a related object to produ~ie a configurated board which is easy to manufacture, which is fire re~istance, which retains structural str~ngth even w~ien exposed to high hea~ resulting ~rom fire, which is rigid and stif~ and resists bending and warping 7 whi~h has excellent heat insulation capabilities, which has excellent noise insulation capabilities, which is light in weight, which is low in cost, and which enables a configurated board of unexpected strength to be formed by heat pressing the board to a configurated wavy pattern from a batt of inorganic -~
fiber strands.
SUMMARY OF THE PRESENT INVENTION
A configurated board constructed in accordance with a specific embodiment of the pres~nt invention comprises a continuously extending board material formed o~ inorganic fi~er strands which iare mixed with an adhesiv~ and then heat pressed and adhered together in a configurated pattern. The pattern has a wavy curvature in which, on each side of the board, rows of regularly spaced hemispherically shaped depressions alternate side by side with rows of regularly spaced hemispherically shaped projections. In this wavy curvature, each projection in one row :~ :
has four related depressions, in the adjacent rows, which are closely adjacent to and equally spaced from the projection. Each of the depressions in a row on one side of the board corresponds in location to a related projection in the same row on the other side o~ the board.
The top, rounded surfaces of all o~ the hemispherically shaped projections on the same side of the configurated board are disposed substantially in one plane so as to be readily engagable with and attachable to a related, facing surface of a flat wall component when the configurated board is mounted and attached as :.
an integral component between two flat wall components to provide an integrated, structural and/or insulating panel structure.
The configurated board has substantially equal material content in cross section throughout but ha~ a relative high :~
density of material content in the cross sectional thickness located at the top of each hemispherically shaped projection and in the ~our cross sectional thicknesses located in the side wall `' " , ' ' '' ' ~
between each projection and each of the four related depressions in the rows adjacent that projection.
The hemispherical shape and the high density areas associated with each hemispherical shape are effective to resist a force exerted from any direction on the board~ The hemispherically curved skructure and the firmness resulting from the compressed high density materials at the top and in the four locations around the side of the hemispherical structure enable the structure to resist or to minimize bending or warping. The strength provided by the configurated board resists bending when the board is used horizontally or vertically.
The inorganic fiber component strand material, of which the board is formed, is in itself effective to provide both heat and sound insulation. The wavy curvature of the board further provides dead air spaces within the depressions (when the board in incorporated into the integrated panel structure) which are effective to provide sound insulation and which are highly effective to provide heat insulation.
Th~ wavy curvature of the configurated board provides a structure which has a relatively large overall height or thickness to provide high stiffness and strength resulting from the large overall section, even though the thickness of any portion of the board itself embodies relatively little material content and therefore relatively little weight. The wavy curvature ther~fore adds section stiffness over and above the stiffness resulting from the thickness of any particular cross section portion of the board. --~a~
Because the board can be made of inexpensive materials, such as the preferred inorganic fiber components, and because these inorganic fib~r components can be heat pressed with high precision into the dasired struc~ural shape, the board can be manufactured quite inexpensively.
A configurated board which incorporates the structural features noted above and which is effective to function in the ways noted above and which provides the practical benefits noted above constitutes further, specific objects of the present invention.
Other and further objects of the present invention will be apparent from the following description and claims and are illustrated in the accompanying drawings, which by way of illuistration, show preferred embodiments of the present invention and the principles thereof and what are now considerad to be the best modes contemplated for applying these principles. Other ~`
embodiments of the invention embodying the same or equivalent principles may be used and structural changes may be made as desired by those skilled in the art without departing from the present invention and the purview of the appended claims.
BRIEF DESCRI~ION OF THE DRAWING VIEWS
Figure 1 is a plan view of a configurated board constructed in accordance with one embodiment of the present invention.
Figure 2 is a fragmentary view in cross section taken along the line and in the direction indicated by the arrows A--A in Figure 1.
. '' ` ~;' ' .
Figure 3 is a fragmentary view in cross section taken along the line and in the direction indicated by the arrows C--C in Figure 1.
Figure 4 is a fragmentary view in cross section taken along the line and in the direction indicated by the arrows B--B in Figure 1.
Figure 5 is a fragmentary plan view illustrating how the patterned, wavy curvature of the configurated board of the present invention provides hemispherically shaped projections with top and side wall structures effective to resist forces exerted from any direction.
Figure 6 is a fragmentary plan view in cross section taken along the line and in the direction indicated by the arrows D--D
in Fi~ure 1.
Figure 7 is an isometric view showing how a configured board constructed in accordance with one emhodiment of the present invention is positioned between and adhered to two outer, flat wall components to provide an integrat:ed panel structure. Figure 7 has been broken away in parts to show details of construction.
DETAILEP DESCRIPTION OF_THE PREFERRED EMBODIMENTS
A configurated board constructed in accordance with one embodiment of the pre~ent invention is indicated generally hy the reference numeral 11 in Figures 1 and 7 and also in Figures 2-4 ,~
and 6 of the drawings. `
In Figure 7 the configurated board 11 is shown interposed between and adhered to one outer, flat wall component 13 and a , :; , . , . . ,.. . . :
.. ,, : . . . .
. . . ' . : ~ :
- : : .. ... .
., - ,:
"
second outer, flat wall component 15.
In a preferred embodiment the configurated board 11 extends continuously in both longitudinal and lateral directions and is formed of inorganic fiber components which are heat pressed and adhered together by an adhesive in a wavy curvature pattern (which can be best seen in Figure 7).
As shown in Figure 7 the top surface of the configurated board 11 is formed with rows of hemispherically shaped projections 17 which alternate with rows of hemispherically shaped depressions 1~.
The hemispherically shaped projections 17 are formed in regularly spaced alignment in each row, and the hemispherically shaped depressions are formed in regularly spaced alignment in each row.
As can also perhapæ best be seen in Figure 7, a depression 19 on one side of the configurated board corresponds in location to a projection 17 on the other side of the configurated board, and vice versa.
As can also be seen in Figure 7 (and in Figure 1), the projections 17 in one row are longitudinally offset from the depressions l9 in each adjacent row so that each projection 17 has four depressions 19 (in the two adjacent rows) which are closely adjacent to and equally spaced from the projection 17.
This alternating, offset arrangement of the oppositely curved hemispherically shaped structures 17 and 19 enables a configurated board 11 of unexpected strength to be formed by heat pressing the board from a batt of inorganic fiber strands, as ,, .. : ~
-. '~
:::
will be described in more detail below.
l'he top, rounded surfaces of all of the hemispherically shaped projections 17 on one side of the configurated board are disposed substantially in one plane so as to be readily engagable with and attachable to a related, facing, flat wall component.
5ee Figure 7 where it can be seen that the inner surface of the flat wall component 15 engages the rounded tops of the hemispherically shaped projections 17 along the rows of these projections 17.
As best shown in Figure 7, stripes 21 of a high strength adhesive are placed on the inner sur~aces of the flat wall panels 13 and 15 in alignment with the rows of the hemispherical shaped projections 17 and then pressed into engagement with the top surfaces of the rows o~ the hemispherically shaped projections 17 to provide an integrated, structural and/or insulating panel ~tructure. `
This integrated panel structure has high structural strength and stiffness with a minimum of material content and with a minimum of weight. The integrated panel structure provides a high degree of heat and sound insulation. The panel structure, because it incorporates a configurated board formed of inorganic fiber components, is fire and flame resistant; and the panel structure is also effective to retain its strength and stiffness when exposed to high heat re~ulting from an adjacent fire.
In a preferred embodiment the configurated board 11 is, as noted above, formed of inorganic fiber components heat pressed and adhered together. Glue i~ mixed with a batt of strands of glass fibers or strands of rock wool fibers before ~he heat pressing, and tha material is then heat pressed to the wavy curvature, configurated pattern described above and shown in the drawings.
The method of manufacture in which the configurated board 11 is formed by heat pressing enables the surfac~ contours and the cross sectional thickness of the configurated board to be manufactured to precise siæes and measurements with thicknesses held to tolerances within a small rang~ of variation.
Thus, for example, in a specific embodiment in which the overall board thickness T (see Figure 4) was 50 millimeters and the thickness t (see Figure 4) was 2 millimeters, the configurated board 11 can be heat pressed to a size within a range of tolerances of plus or minus 0.2 millimeters.
Heat pressing the inorganic fiber material and glue to the configurated wavy curvature pattern for the board 11 to form the configurated board 11 with the alternating rows of hemispherical projections and depressions creates a board of exceptional strength.
As best shown in Figures 2 and 4~ different parts of the board are heat pressed to provide higher dansities of the material in the areas 23 existing on the rounded tops 23 of the projections 17 (and the rounded bottoms o~ the corresponding depressions 19) and in each o~ the four areas 25 which are located between each projection 17 and the four related depressions 19 in the rows adjacent each projection 17. These areas of high density coact to provide a structural firmness g .
~ r 9 $~ ~
throughout the configurated ~oard 11 to create exceptional strength.
In other areas 27 (see Figure 2 and Figure 3) the amount of material in the cross section is substantially the same amount of ~
material as the amount of material in the cross sections 23 and 25, but the materials in the areas 27 are not compressed to as ;
high a density of the materials in tha areas 23 and 25.
In a specific embodiment of the present invention tha batt .
of inorganic fiber material from which the configurated board 11 was heat pressed had a weight oE 1600 grams per square meter, the dimension of the thickness t (areas 23 and 25 in Figure 4) was 4 millimetars, the density of the areas 23 and 25 was 400 kilograms per cubic meter, the dimension of T (the overall height of the configuraked board 11 as shown in Figure 4) was 40 millimeters, and the density of the area 27 (see Fig. 2) was 40 kilograms per cubic meter.
As shown by the force vector diagram in Figure 5, the ,.
hemispherical shape and the high density areas 23 and 25 associated with each depression 19 and each projection 17 enable the hemispherically shaped projection and depression structure to be ef~ective to resist a force exerted from any direction on the ~:
structure. Thus, whether the force comes from the direction W or X or Y or Z, the hemispheri~.ally curved structure and the firmness resulting from the compressed high density materials at the top and in the four locations around the side of the hemispherical structure enable the structure to resist or to ~-~
minimize deflection or bending which could otherwise result from '. ', ' ' .'~ ' ~' ' ' .. ' the application of one of the force vectors.
The strength provided by the configurated board 11 prevents bending when the board is used horizontally or ~ertically.
The inorganic fiber component strand material of which the board is formed is in itself effective to provide both heat and sound insulation.
The wavy curvature of the board 11 further provides dead air spaces within the depressions 19 which are e~fective to provide sound insulation and which are highly effective to provide heat insulation when the board 11 is incorporated into the integrated panel structure shown in Figure 7 The integrated panel structure shown in Figure 7 is therefore quite useful as a building construction material for partitions, doors, ceilings, walls and floors.
In addition, the panel structure is particularly useful in apartment complexes and condominium complexes to reduce noise and to insulate between the apartment or condo units.
In one particular embodiment of the present invention the total thickness of the integrated panel shown in Figure 7 was 50 millimeters. The configurated board 11 was made of heat pressed glass wool fiber~ ~dhered together by an intermixed glue, and the overall thickness of the configurated board 11 was 42 millimeters. The density of tha batt of glass wool fibers prior to heat pressin~ to the patterned configuration shown was 400 kilograms per cubic meter. The weight of the batt of glass wool starting material was 1.6 kilograms per square meter. The total weight of the integrated panel product was 4.8 kilograms per ~ -,' , ' - ' . . .
' ~ ''. ' , :
square meter (when the flat wall pan~els 13 and 15 were also made by heat pressing the same glass wool fiber batt material as was used for making the configurated board 11~.
The resulting panel structure had a strength which was 3 to 3~ the strength of a panel structure formed in accordance with JSIA 6322 Standard ~easurement Rule tthe Japanese Standard); and the amount of required glass wool materials needed for the Japanese Standard was 2.6 to 3.5 times l.arger (by using conventional techniques) than the amount of glass wool materials employed in this specific embodim~nt of the present invention.
This embodiment of the present invention was also lighter in weight than the product formed under the Japanese Standard. ..
~he wavy curvature of the configurated board 11 provides a structure whic:h has relatively large overall thickness T (see Figure 4) to provide high stiffness and strength resulting ~rom the large section. But the wavy curvature of the configurated board 11 embodies relatively little material content (and therefore relatively little material weight) in the actual cross section of any particular portion (such as the thickness t) of the configurated board 11. The wavy curvature therefore adds section stiffness over an~ above that available from the stiffness resulting from the thickness of any particular portion of the cross section of the configurated board 11 The configurated board 11 i5 therefore much more resistant to warping or bending than is a flat board having exactly the same material content as the configurated board 11.
The way in which the hemispherlcal structures are embodied , , .......... , , - . :
.: ~ . .:,, ~ . ,:
~ '~
~ ~f~
in spaced alignment in a row and in offset alternation between adjacant oppositely curved hemispherically shaped structures in adjacent rows produces unexpected benefits of increased strength and rigidity and resistance to forces exerted in any direction.
The configurated board 11 is therefore substantially equally resistant to deflection or deformation from a given force, regardless of the direction from which th~ given force is applied.
Because the configurated board 11 can be made of inexpensiv~
materials, such as the preferred inorganic fiber components, and because these inorganic fiber components can be heat pressed with high precision to the desired structural shape, the board 11 can be manufactured quite inexpensively.
Because the configurated board 11 can be constructed to be very light in weight and because the wavy curvature pattern of the board i5 highly resistant to warping or deformation, the light weight and structural rigidity combined to enhance resistance to any flexing, bending or warping which could result from the weight of a panel structure itself.
The configurated board 11 of the present invention can be incorporated into a panel structure in which ths flat boards 13 and 15 lsee Figure 7) are made out of either glass fiber strands, rock wool strands, plywood, or plasterboard.
The configurated board of the present invention avoids the high cost of production of fire resistant panels having chemically treated honeycomb or aluminum honeycomb, because it is more economical to use fireproof inorganic fiber materials than . ..,.. . ~ . , , ,: ;
, it is to use chemically treated paper honeycomb or aluminum honeycomb to achieve fire resistance.
The configurated board 11 formed of inorganic fiber components in accordance with the present invention is stronger and lighter in weight than convantional products.
Because the materials used are formed with heat, the configurated board 11 of the pres~nt invention can be manufactured to precise sizes and measurements and the thickness of the board can be maintained at tolerances within a small range of variation (even when starting the manufacture with batts of loose strand materials).
The configurated board 11 of the present invention (incorporating the alternating rows of hemispherical projection :~
and depression structures in offset relation in side by side rows) is a configurated board which is easy to manu~acture, which is fire resistant, which retains structural strength even when exposed to high heat resultinig from fire, which is rigid and stiff and resists bending andi warping, which has excellent heat insulation capabilities, which has excellent noisa insulation capabilities, which is light in weight and which is low in cost.
While I have illustrated and desc~ibed the prePerred embodiments o~ my invention, it is to be understood that these are capable of variation and modification, and I therefore do not ~;
wish to be limited to the precise details set forthl but desire to avail myself of such changes and alterations as fall within the purview of the following claims: :
BACKGROUND OF THE INVEN~ION
This invention relates to a conEigurated board which is constructed to be positioned between and adhered to two outer, flat wall components to provide an integrated structural and/or insulating panel structure.
This invention relates particularly to a configurated board formed of inorganic fiber component strands which are heat -~
pressed and adhesively adhered together in a wavy curvature in which rows of hemispherical~y shaped depressions alternate with rows of hemispherically shaped projections.
This invention has particular application to structural and insulating panels which need to have a high degree of ~ire reslstance.
Panel structures used in the con6truction industry as indoor construction materials may be used as partitions, doors, ceiling panels, wall panels, and floor panels. Such panels, particularly in apartment complexes and condominium complexes, may need to be constructed so as to reduce noise and to insulate between apartment or condo units.
If is often nece~sary that such panel structures have a relatively high degree of fire resistance.
To achieve a certain level of fire resistance, some such panels have included paper honeycomb as a core between sections ~;
of plywoQd or other flat outer panel materials. The honeycomb paper had to be treated to insure fire resistance.
Other such panels have included the u~e of aluminum or steel : ,, . . : ., . , ~
: ' ;' .. , '~ ' ::
~ "., - ~ :
::
.
as a core.
Glass wool has also been used as a core, primarily for insulation and noise reduction.
The uses of chemically treated paper, aluminum, steel or glass wool as a core for such panel structures have presented certain problems. These problems have included high cost and complexity of manufacturing procedures.
It is a primary ob~ect of the present invention to construct a configurated board which can be used as an internal component in an integrated structural and~or insulating panel stru~ture and which overcomes the problems presented by core materials previously llsed.
It is a related object to form a configurated board of inorganic fiber strands heat pressed and adhesively adhered together into a wavy curvature -- a curvature in which, on each ~
side of the board, rows of hemispherically shaped depressions ' alternate with rows of hemispherically shaped projections.
It is a related object to produ~ie a configurated board which is easy to manufacture, which is fire re~istance, which retains structural str~ngth even w~ien exposed to high hea~ resulting ~rom fire, which is rigid and stif~ and resists bending and warping 7 whi~h has excellent heat insulation capabilities, which has excellent noise insulation capabilities, which is light in weight, which is low in cost, and which enables a configurated board of unexpected strength to be formed by heat pressing the board to a configurated wavy pattern from a batt of inorganic -~
fiber strands.
SUMMARY OF THE PRESENT INVENTION
A configurated board constructed in accordance with a specific embodiment of the pres~nt invention comprises a continuously extending board material formed o~ inorganic fi~er strands which iare mixed with an adhesiv~ and then heat pressed and adhered together in a configurated pattern. The pattern has a wavy curvature in which, on each side of the board, rows of regularly spaced hemispherically shaped depressions alternate side by side with rows of regularly spaced hemispherically shaped projections. In this wavy curvature, each projection in one row :~ :
has four related depressions, in the adjacent rows, which are closely adjacent to and equally spaced from the projection. Each of the depressions in a row on one side of the board corresponds in location to a related projection in the same row on the other side o~ the board.
The top, rounded surfaces of all o~ the hemispherically shaped projections on the same side of the configurated board are disposed substantially in one plane so as to be readily engagable with and attachable to a related, facing surface of a flat wall component when the configurated board is mounted and attached as :.
an integral component between two flat wall components to provide an integrated, structural and/or insulating panel structure.
The configurated board has substantially equal material content in cross section throughout but ha~ a relative high :~
density of material content in the cross sectional thickness located at the top of each hemispherically shaped projection and in the ~our cross sectional thicknesses located in the side wall `' " , ' ' '' ' ~
between each projection and each of the four related depressions in the rows adjacent that projection.
The hemispherical shape and the high density areas associated with each hemispherical shape are effective to resist a force exerted from any direction on the board~ The hemispherically curved skructure and the firmness resulting from the compressed high density materials at the top and in the four locations around the side of the hemispherical structure enable the structure to resist or to minimize bending or warping. The strength provided by the configurated board resists bending when the board is used horizontally or vertically.
The inorganic fiber component strand material, of which the board is formed, is in itself effective to provide both heat and sound insulation. The wavy curvature of the board further provides dead air spaces within the depressions (when the board in incorporated into the integrated panel structure) which are effective to provide sound insulation and which are highly effective to provide heat insulation.
Th~ wavy curvature of the configurated board provides a structure which has a relatively large overall height or thickness to provide high stiffness and strength resulting from the large overall section, even though the thickness of any portion of the board itself embodies relatively little material content and therefore relatively little weight. The wavy curvature ther~fore adds section stiffness over and above the stiffness resulting from the thickness of any particular cross section portion of the board. --~a~
Because the board can be made of inexpensive materials, such as the preferred inorganic fiber components, and because these inorganic fib~r components can be heat pressed with high precision into the dasired struc~ural shape, the board can be manufactured quite inexpensively.
A configurated board which incorporates the structural features noted above and which is effective to function in the ways noted above and which provides the practical benefits noted above constitutes further, specific objects of the present invention.
Other and further objects of the present invention will be apparent from the following description and claims and are illustrated in the accompanying drawings, which by way of illuistration, show preferred embodiments of the present invention and the principles thereof and what are now considerad to be the best modes contemplated for applying these principles. Other ~`
embodiments of the invention embodying the same or equivalent principles may be used and structural changes may be made as desired by those skilled in the art without departing from the present invention and the purview of the appended claims.
BRIEF DESCRI~ION OF THE DRAWING VIEWS
Figure 1 is a plan view of a configurated board constructed in accordance with one embodiment of the present invention.
Figure 2 is a fragmentary view in cross section taken along the line and in the direction indicated by the arrows A--A in Figure 1.
. '' ` ~;' ' .
Figure 3 is a fragmentary view in cross section taken along the line and in the direction indicated by the arrows C--C in Figure 1.
Figure 4 is a fragmentary view in cross section taken along the line and in the direction indicated by the arrows B--B in Figure 1.
Figure 5 is a fragmentary plan view illustrating how the patterned, wavy curvature of the configurated board of the present invention provides hemispherically shaped projections with top and side wall structures effective to resist forces exerted from any direction.
Figure 6 is a fragmentary plan view in cross section taken along the line and in the direction indicated by the arrows D--D
in Fi~ure 1.
Figure 7 is an isometric view showing how a configured board constructed in accordance with one emhodiment of the present invention is positioned between and adhered to two outer, flat wall components to provide an integrat:ed panel structure. Figure 7 has been broken away in parts to show details of construction.
DETAILEP DESCRIPTION OF_THE PREFERRED EMBODIMENTS
A configurated board constructed in accordance with one embodiment of the pre~ent invention is indicated generally hy the reference numeral 11 in Figures 1 and 7 and also in Figures 2-4 ,~
and 6 of the drawings. `
In Figure 7 the configurated board 11 is shown interposed between and adhered to one outer, flat wall component 13 and a , :; , . , . . ,.. . . :
.. ,, : . . . .
. . . ' . : ~ :
- : : .. ... .
., - ,:
"
second outer, flat wall component 15.
In a preferred embodiment the configurated board 11 extends continuously in both longitudinal and lateral directions and is formed of inorganic fiber components which are heat pressed and adhered together by an adhesive in a wavy curvature pattern (which can be best seen in Figure 7).
As shown in Figure 7 the top surface of the configurated board 11 is formed with rows of hemispherically shaped projections 17 which alternate with rows of hemispherically shaped depressions 1~.
The hemispherically shaped projections 17 are formed in regularly spaced alignment in each row, and the hemispherically shaped depressions are formed in regularly spaced alignment in each row.
As can also perhapæ best be seen in Figure 7, a depression 19 on one side of the configurated board corresponds in location to a projection 17 on the other side of the configurated board, and vice versa.
As can also be seen in Figure 7 (and in Figure 1), the projections 17 in one row are longitudinally offset from the depressions l9 in each adjacent row so that each projection 17 has four depressions 19 (in the two adjacent rows) which are closely adjacent to and equally spaced from the projection 17.
This alternating, offset arrangement of the oppositely curved hemispherically shaped structures 17 and 19 enables a configurated board 11 of unexpected strength to be formed by heat pressing the board from a batt of inorganic fiber strands, as ,, .. : ~
-. '~
:::
will be described in more detail below.
l'he top, rounded surfaces of all of the hemispherically shaped projections 17 on one side of the configurated board are disposed substantially in one plane so as to be readily engagable with and attachable to a related, facing, flat wall component.
5ee Figure 7 where it can be seen that the inner surface of the flat wall component 15 engages the rounded tops of the hemispherically shaped projections 17 along the rows of these projections 17.
As best shown in Figure 7, stripes 21 of a high strength adhesive are placed on the inner sur~aces of the flat wall panels 13 and 15 in alignment with the rows of the hemispherical shaped projections 17 and then pressed into engagement with the top surfaces of the rows o~ the hemispherically shaped projections 17 to provide an integrated, structural and/or insulating panel ~tructure. `
This integrated panel structure has high structural strength and stiffness with a minimum of material content and with a minimum of weight. The integrated panel structure provides a high degree of heat and sound insulation. The panel structure, because it incorporates a configurated board formed of inorganic fiber components, is fire and flame resistant; and the panel structure is also effective to retain its strength and stiffness when exposed to high heat re~ulting from an adjacent fire.
In a preferred embodiment the configurated board 11 is, as noted above, formed of inorganic fiber components heat pressed and adhered together. Glue i~ mixed with a batt of strands of glass fibers or strands of rock wool fibers before ~he heat pressing, and tha material is then heat pressed to the wavy curvature, configurated pattern described above and shown in the drawings.
The method of manufacture in which the configurated board 11 is formed by heat pressing enables the surfac~ contours and the cross sectional thickness of the configurated board to be manufactured to precise siæes and measurements with thicknesses held to tolerances within a small rang~ of variation.
Thus, for example, in a specific embodiment in which the overall board thickness T (see Figure 4) was 50 millimeters and the thickness t (see Figure 4) was 2 millimeters, the configurated board 11 can be heat pressed to a size within a range of tolerances of plus or minus 0.2 millimeters.
Heat pressing the inorganic fiber material and glue to the configurated wavy curvature pattern for the board 11 to form the configurated board 11 with the alternating rows of hemispherical projections and depressions creates a board of exceptional strength.
As best shown in Figures 2 and 4~ different parts of the board are heat pressed to provide higher dansities of the material in the areas 23 existing on the rounded tops 23 of the projections 17 (and the rounded bottoms o~ the corresponding depressions 19) and in each o~ the four areas 25 which are located between each projection 17 and the four related depressions 19 in the rows adjacent each projection 17. These areas of high density coact to provide a structural firmness g .
~ r 9 $~ ~
throughout the configurated ~oard 11 to create exceptional strength.
In other areas 27 (see Figure 2 and Figure 3) the amount of material in the cross section is substantially the same amount of ~
material as the amount of material in the cross sections 23 and 25, but the materials in the areas 27 are not compressed to as ;
high a density of the materials in tha areas 23 and 25.
In a specific embodiment of the present invention tha batt .
of inorganic fiber material from which the configurated board 11 was heat pressed had a weight oE 1600 grams per square meter, the dimension of the thickness t (areas 23 and 25 in Figure 4) was 4 millimetars, the density of the areas 23 and 25 was 400 kilograms per cubic meter, the dimension of T (the overall height of the configuraked board 11 as shown in Figure 4) was 40 millimeters, and the density of the area 27 (see Fig. 2) was 40 kilograms per cubic meter.
As shown by the force vector diagram in Figure 5, the ,.
hemispherical shape and the high density areas 23 and 25 associated with each depression 19 and each projection 17 enable the hemispherically shaped projection and depression structure to be ef~ective to resist a force exerted from any direction on the ~:
structure. Thus, whether the force comes from the direction W or X or Y or Z, the hemispheri~.ally curved structure and the firmness resulting from the compressed high density materials at the top and in the four locations around the side of the hemispherical structure enable the structure to resist or to ~-~
minimize deflection or bending which could otherwise result from '. ', ' ' .'~ ' ~' ' ' .. ' the application of one of the force vectors.
The strength provided by the configurated board 11 prevents bending when the board is used horizontally or ~ertically.
The inorganic fiber component strand material of which the board is formed is in itself effective to provide both heat and sound insulation.
The wavy curvature of the board 11 further provides dead air spaces within the depressions 19 which are e~fective to provide sound insulation and which are highly effective to provide heat insulation when the board 11 is incorporated into the integrated panel structure shown in Figure 7 The integrated panel structure shown in Figure 7 is therefore quite useful as a building construction material for partitions, doors, ceilings, walls and floors.
In addition, the panel structure is particularly useful in apartment complexes and condominium complexes to reduce noise and to insulate between the apartment or condo units.
In one particular embodiment of the present invention the total thickness of the integrated panel shown in Figure 7 was 50 millimeters. The configurated board 11 was made of heat pressed glass wool fiber~ ~dhered together by an intermixed glue, and the overall thickness of the configurated board 11 was 42 millimeters. The density of tha batt of glass wool fibers prior to heat pressin~ to the patterned configuration shown was 400 kilograms per cubic meter. The weight of the batt of glass wool starting material was 1.6 kilograms per square meter. The total weight of the integrated panel product was 4.8 kilograms per ~ -,' , ' - ' . . .
' ~ ''. ' , :
square meter (when the flat wall pan~els 13 and 15 were also made by heat pressing the same glass wool fiber batt material as was used for making the configurated board 11~.
The resulting panel structure had a strength which was 3 to 3~ the strength of a panel structure formed in accordance with JSIA 6322 Standard ~easurement Rule tthe Japanese Standard); and the amount of required glass wool materials needed for the Japanese Standard was 2.6 to 3.5 times l.arger (by using conventional techniques) than the amount of glass wool materials employed in this specific embodim~nt of the present invention.
This embodiment of the present invention was also lighter in weight than the product formed under the Japanese Standard. ..
~he wavy curvature of the configurated board 11 provides a structure whic:h has relatively large overall thickness T (see Figure 4) to provide high stiffness and strength resulting ~rom the large section. But the wavy curvature of the configurated board 11 embodies relatively little material content (and therefore relatively little material weight) in the actual cross section of any particular portion (such as the thickness t) of the configurated board 11. The wavy curvature therefore adds section stiffness over an~ above that available from the stiffness resulting from the thickness of any particular portion of the cross section of the configurated board 11 The configurated board 11 i5 therefore much more resistant to warping or bending than is a flat board having exactly the same material content as the configurated board 11.
The way in which the hemispherlcal structures are embodied , , .......... , , - . :
.: ~ . .:,, ~ . ,:
~ '~
~ ~f~
in spaced alignment in a row and in offset alternation between adjacant oppositely curved hemispherically shaped structures in adjacent rows produces unexpected benefits of increased strength and rigidity and resistance to forces exerted in any direction.
The configurated board 11 is therefore substantially equally resistant to deflection or deformation from a given force, regardless of the direction from which th~ given force is applied.
Because the configurated board 11 can be made of inexpensiv~
materials, such as the preferred inorganic fiber components, and because these inorganic fiber components can be heat pressed with high precision to the desired structural shape, the board 11 can be manufactured quite inexpensively.
Because the configurated board 11 can be constructed to be very light in weight and because the wavy curvature pattern of the board i5 highly resistant to warping or deformation, the light weight and structural rigidity combined to enhance resistance to any flexing, bending or warping which could result from the weight of a panel structure itself.
The configurated board 11 of the present invention can be incorporated into a panel structure in which ths flat boards 13 and 15 lsee Figure 7) are made out of either glass fiber strands, rock wool strands, plywood, or plasterboard.
The configurated board of the present invention avoids the high cost of production of fire resistant panels having chemically treated honeycomb or aluminum honeycomb, because it is more economical to use fireproof inorganic fiber materials than . ..,.. . ~ . , , ,: ;
, it is to use chemically treated paper honeycomb or aluminum honeycomb to achieve fire resistance.
The configurated board 11 formed of inorganic fiber components in accordance with the present invention is stronger and lighter in weight than convantional products.
Because the materials used are formed with heat, the configurated board 11 of the pres~nt invention can be manufactured to precise sizes and measurements and the thickness of the board can be maintained at tolerances within a small range of variation (even when starting the manufacture with batts of loose strand materials).
The configurated board 11 of the present invention (incorporating the alternating rows of hemispherical projection :~
and depression structures in offset relation in side by side rows) is a configurated board which is easy to manu~acture, which is fire resistant, which retains structural strength even when exposed to high heat resultinig from fire, which is rigid and stiff and resists bending andi warping, which has excellent heat insulation capabilities, which has excellent noisa insulation capabilities, which is light in weight and which is low in cost.
While I have illustrated and desc~ibed the prePerred embodiments o~ my invention, it is to be understood that these are capable of variation and modification, and I therefore do not ~;
wish to be limited to the precise details set forthl but desire to avail myself of such changes and alterations as fall within the purview of the following claims: :
Claims (13)
1. A configurated board constructed to be positioned between and adhered to two outer, flat wall components to provide an integrated structural and/or insulating panel structure, said configurated board comprising a continuously extending board material formed of inorganic fiber components heat pressed and adhered together by an adhesive in a configurated pattern, said configurated board having a patterned, wavy curvature in which, on each side of the board, rows of regularly spaced hemispherically shaped depressions alternate side by side with rows of regularly spaced hemispherically shaped projections so that each projection has four related depressions, in the adjacent rows, which are closely adjacent to and equally spaced from the projection, and wherein each of the depressions in a row on one side corresponds in location to a related projection in the same row on the other side of the configurated board, and wherein the top, rounded surfaces of all of the hemispherically shaped projections on the same side of the configurated board are disposed substantially in one plane so as to be readily engagable with and attachable to a related, facing surface of a flat wall component when the configurated board is mounted and attached as an internal component between two flat wall components to provide an integrated, structural and/or insulating panel structure.
2. The invention defined in Claim 1 wherein the configurated board has substantially equal material content in cross section throughout but has a relatively high density of material content in the cross sectional thickness located at the top of each hemispherically shaped projection and in the cross sectional thicknesses located between each projection and each of the four related depressions in the rows adjacent that projection.
3. The invention defined in Claim 2 wherein said thicknesses of high density coact to provide a structural firmness throughout the entire configurated board.
4. The invention defined in claim 2 wherein the said thicknesses of high density are effective to resist forces exerted from any direction on the projection.
5. The invention defined in claim 1 wherein the board material is formed of glass fiber strands pressed and adhered together to provide fire resistance and relatively high strength at light weight.
6. The invention defined in claim 1 wherein the board material is formed of rock wool strands pressed and adhered together to provide fire resistance and relatively high strength at light weight.
7. The invention defined in claim 1 wherein the configurated board is formed by heat pressing to permit manufacturing to precise sizes and measurements with thicknesses held to tolerances within a small range of variation.
8. The invention defined in claim 1 including two flat wall components with each flat wall component engaged with the top, rounded surfaces of all of the hemispherically shaped projection on one related side of the configurated board and adhered to the engaged surfaces by a high strength adhesive to provide an integrated panel structure in which the inner configurated board is disposed between and is adhesively adhered to the two outer, flat wall components.
9. The invention defined in claim 8 wherein each of the outer, flat wall components is formed of inorganic fiber components heat pressed and adhered together by an adhesive during the heat pressing.
10. The invention defined in claim 8 wherein each of the outer, flat wall components is made of plywood.
11. The invention defined in claim 8 wherein each of the outer, flat wall components is made of plasterboard.
12. The invention defined in claim 1 wherein the weight of the configurated board is 1.6 kilogram per square meter.
13. An integrated panel structure constructed for use as a structural and/or insulating panel, said integrated structural panel comprising, two outer, flat wall components, said configurated board comprising a continuously extending board material pressed into a configurated pattern, said configurated board having a patterned, wavy curvature in which, on each side of the board, rows of hemispherically shaped depressions alternate with rows of hemispherically shaped projections, and wherein the depressions on one side correspond in location to the projections on the other side of the configurated board, and wherein the top, rounded surfaces of all of the hemispherically shaped projections on the same side of the configurated board are disposed substantially in one plane and are attached by an adhesive to the facing surface of the related flat wall component.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2-89722 | 1990-08-27 | ||
| JP1990089722U JPH0544879Y2 (en) | 1990-08-27 | 1990-08-27 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2049827A1 true CA2049827A1 (en) | 1992-02-28 |
Family
ID=13978660
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002049827A Abandoned CA2049827A1 (en) | 1990-08-27 | 1991-08-26 | Fiber core materials used for board |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JPH0544879Y2 (en) |
| CA (1) | CA2049827A1 (en) |
| SE (1) | SE9102436L (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117162541A (en) * | 2023-11-03 | 2023-12-05 | 北京玻钢院复合材料有限公司 | Sandwich board with hemispherical honeycomb core layer and preparation method thereof |
-
1990
- 1990-08-27 JP JP1990089722U patent/JPH0544879Y2/ja not_active Expired - Lifetime
-
1991
- 1991-08-23 SE SE9102436A patent/SE9102436L/en not_active Application Discontinuation
- 1991-08-26 CA CA002049827A patent/CA2049827A1/en not_active Abandoned
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117162541A (en) * | 2023-11-03 | 2023-12-05 | 北京玻钢院复合材料有限公司 | Sandwich board with hemispherical honeycomb core layer and preparation method thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH0544879Y2 (en) | 1993-11-15 |
| SE9102436D0 (en) | 1991-08-23 |
| JPH0446500U (en) | 1992-04-20 |
| SE9102436L (en) | 1992-02-28 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued |