CA2181407A1 - Panel and method of making panel - Google Patents
Panel and method of making panelInfo
- Publication number
- CA2181407A1 CA2181407A1 CA 2181407 CA2181407A CA2181407A1 CA 2181407 A1 CA2181407 A1 CA 2181407A1 CA 2181407 CA2181407 CA 2181407 CA 2181407 A CA2181407 A CA 2181407A CA 2181407 A1 CA2181407 A1 CA 2181407A1
- Authority
- CA
- Canada
- Prior art keywords
- panel
- panel member
- reinforcing
- portions
- interior surface
- 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
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- Laminated Bodies (AREA)
Abstract
A panel for use in constructing a structure or architecture, including a substantially rigid generally planar first panel member, a substantially rigid generally planar second panel member spaced apart from and generally parallel to the first panel member thereby creating a space therebetween, a plurality of reinforcing elements disposed intermediate the first panel member and the second panel member proximate the space for adding structural integrity and strength to the panel, and an insulating substance substantially filling the space.
Description
. 218~4~
s 7 This invention relates to paneling.
9 More 2articul2rly, this invention relates to 10 prefabrlcated p2neling.
Il 12 In a further and more specific aspect, the instant ], invention relates to prefabricated paneling for use in 14 constructing 2 structure.
IS In architecture 2nd design, decorative treatment of 19 walls, ceilings, doors, and furniture has historically consisted of joining a series of wide, thin sheets of wood, 21 called p2nels, with narro~er, thicker s3~rips of wood. Prior 22 to the 'ûth century, paneling was almost al~ays made of ~ .
s 7 This invention relates to paneling.
9 More 2articul2rly, this invention relates to 10 prefabrlcated p2neling.
Il 12 In a further and more specific aspect, the instant ], invention relates to prefabricated paneling for use in 14 constructing 2 structure.
IS In architecture 2nd design, decorative treatment of 19 walls, ceilings, doors, and furniture has historically consisted of joining a series of wide, thin sheets of wood, 21 called p2nels, with narro~er, thicker s3~rips of wood. Prior 22 to the 'ûth century, paneling was almost al~ays made of ~ .
2, either oalc or pi~e, and was typically manufactured to 24 feature :simple or lavis~1 styli7ed carvings and other =
decorative features.
]
i 2181407 Beglnnlng in the ~0t11 century, a wide varlety of 2 materials came into use in the manufactur~e of paneling. For 3 instance, solld wood e.g. walnut, mahogany, birch, and 4 redwood, became commonplace mzterials fQr the construction S of paneLing. Other materi21s that became useful in the 6 construction of paneling rurther consis.ed of .plywood (a 7 thin wood veneer on a plywood base), vinyl with surface 8 imitating wood grain, hardboard (or pressed wood), pegboard, 9 and even transLucent materials . e.g. ~;UCITE~. ~ith the advent of: technological advances in the construction of 11 automobiles, sea-golng ~-ehicles, airplanes, and space 12 vehicles, = the importance of constructinq paneling resistant 13 to environmental elements, corroslon, and large vari~nces in 14 temperature and pressure became very important for use in constructing such apparatus. ~ For instance, the panellng 16 used in .the - cpnstruction of many aerospace vehicles is 17 typically corstructed of hiqh impact, heat resistart ceramlc 18 composite: substances .
~9 Prefabricated panellng can be used for constructing an 21 array structures e.g. housés, cars, motor-homes, mobile-22 homes, planes, and other similar structures. It will be 23 readily appreciated that paneling used for the construction 24 of such structures needs to have high insulating characterlstics fol~ res' sting larSIe variances in -. 2~814Q7 temperature, and also r.eeds to be possess sufficient 2 strength in order to be resist2nt to dam2ge resulting from 3 impact and to provide structural integrity. However, most 4 paneling that is both strong while having good insulating S characteristics, is heavy. As a consequence, there is a 6 need to produce.paneling for use in constructing a structure 7 that is not only strong, resi~lien~, and a good insulator, but also light so that structures may be easily constructed.
It would be highly advantageous, therefore, to remedy 11 the foregoing and other~ ~eficiencies i~herent in the prior 12 art.
14 AccordingIy, it is an object of the present invention 15 to provide a new ~nd useful panel for use in constructing a 16 selected structure.
1~3 Another objcct of the present invelltion is to provide a 19 panel that is strorg.
21 ~nother obj ect of ~the present invention lS to 22 provide a panel thât is light.
. 21814Q7 Still another object of the present inYention is to 2 provide a panel th2t is ~ a good insul2tor ag2inst large 3 variations in temperature.
Yet another object of the instant invention is to 6 provide 2 p2nel th2t may be used for constructing motor-7 homes znd the like.
9 Yet still a~other object of the instznt invention is to provide z pznel thzt is ezsy znd inexpensive tq mznufzcture 12 Yet a further object of .he invention is to provide z 13 panel thzt is resistant to breakage. -Still a further object of the immediate invention is to 16 provide a pallel that is resistant tq the deteriorating 17 affects qf oxygen, water ~-auid or vapor, salts, znd other 18 environmental elements.
Yet z further obj ect of the invention is to provide z 21 new znd useful method of const,ructing z pznel.
23 Still z further obj ect of the invention is to 24 provide z new znd useful method of joining z plurality of ~5 pa~els togeth4~.
. . 21814~7 Yet still a further object of the invention is to '~ provide a: panel that is easy to repair. - -3 Briefly, to achieve the desired sbjects of the instant 4 invention in-accordance with a preferred embodiment thereof, provided is a panel for~ use in constructing a structure or 6 architecture, a method of manufacturing a panel, and a 7 method of joining a plurality of panel memlsers. The panel 8 includes a substantially rigid generally planar first panel 9 member and a substantially rigid generally planar second panel me.~ber spaced apart '~rom and generally parallel to the 11 first panel member thereby creating a space therebetween.
12 Disposed.intermediate the first paneI member and the second 13 panel member proximate the space exist an insulating 14 substance substantially fl!ling the space and a reinforcing means comprising a plurality of reinforcing elements for 16 adding structural integrity and strength to t1le panel.
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18 The method of manufacturing a panel includes the steps 19 of providing a substantially rigid generally planar first panel member and 2 substantially rigid generally planar 21 second panel member spaced~~apa~rt from and generally parallel 22 to the first panel member ~ thereby creating a space 23 therebetween. The step of providing the first panel memoer 24 includes the steps of superimposing a plurality of layers of 25 material, and firmly uniting the plurality of layers of ~ . 2~81437 material together wlth a bonding substance. Furthermore, 2 the step of providing t~le second panel member likewise 3 includes the steps of firn~ly uniting a~ pluraIity of layers 4 of material together with a bondil~g substance. ~he next S step involves Introducing reinforcing means proximate the 6 space for adding structural~ integrity and strength to the 7 panel, and then substanti ally filling the space with an 8 insulating substance.
The method of joining a plurality of panel members Il includes the steps of providing a substantially planar firs~c 17 panel and a substantially planar second panel, providing a 13 first recessed portion proximate the first panel and 14 providing a second recessed portion proYimate the second 15 panel, juxtaposing the first recessed portion proximate the 16 second recessed portion, and securing the first panel and 17 the second panel together by preferably disposing lamination 1S proximate the first and second recessed portions to form a 19 substantially planar panel ~se~tion.
In the accompanying drawings:
9 Flg. 1 is a perspecti~e view of an,, eml~odiment of the instant invention constructed ln accordance with the II preferred embodimenti 13 Fig. 2 is an enlarged fragmentary perspective view of ,,, 4 po~tions of the e~od~, m.ent ~eplcted in Fig . 1;
16 Fig. 3 is a vie~1 very similar to the view of Fiq. 2;
18 Fig. 4 is a fra~mentary perspective view ,of a mold ~or 19 use in constructing the embodiment depicted in Fig. l, and further illustrating a human hand holding a cleaning device, 21 for use in cleaning portions o~ ~he mold as showni 23 Fig. 5 is a perspective view of the entire mold first 24 shown in combination ', ith Fig. 4, and further illustrating a 21~1407 spraylng device spraylng ~ a substance upon portions of the 2 mold;
4 Fig. 6 is a perspecti~e view of a pair of human hands S applying a layer ~or use in constructiDn of the embodiment 6 shown in Fig. 1, and furtrler showing the layer as it would 7 appear being disposed upon portions of the mold depicted in 8 Fig. 5;
Fig. 7 is a perspec'ive view very~ similar to the view I ] of Fig. 6, and further il lustrating a spray device spraying 7a substance upon portions - of the layer, and a human hand ~3holding a sErreading device for spreading a substance upon 14portions of the layer;
16 Fig. a is a perspect~ ve view very similar to the view 17 of Fig. ~, and ~urther lllustrating a roller device 18spreading a substance upor another layer superimposed atop 19the layer first illustrated in Fig. 6;
~ Fig. 9 is an enl~rged fragmentary side elevational view 22 of a first panel member of the instant invention as first 23shown in Fig. 2;
2~1407 Fig. lO is a ~ront eleva[ional view oi pGrtio11s of the 2 instant invention as- illustrated during construction o~ the 3 embodlment depicted in Fig. l, and further illustrating a 4 plurality of reinforcing ~lbs positioned upon portions of S the first panel meri~er;
7 Fig. ll is a perspectlve view~ very similar to the view g o Fig. 10, and further illustrating one of the pluraIity of 9 reinforcing ribs being secured to portions of the first ]O panel member; ~ -Il ]2 Fig. 1'7 `i5 an e~large~ fra~entary perspective vie~ of ]3 one of the plurality of reinforcing ribs as shown, and ~4 further having a strip of reinforcirlg material applied thereto; _ .
17 Fig. 13 i5 cn enlarged fragmentary front 1g elevational view o. portions of the instant: lnvention ]9 illustrating one of the plurality of reinforcing ribs with ~0 the strip of reinforclng material secured thereto;
2]
22 Fig. 14 is an enlarged fragmentary perspective view of ~, one of the plurality of reinfDrcing ribs being laminated to 24 portions of the first panel member;
]O
] Fig. 15 lS an enl2rged ~ragmentary ~ront elevational 2 view of portions of the lnstant invention, very similar to 3 the view of Fig. 10, and f~lrther~ illustrating the plu~ali.y 4 of reinforcing ribs as they would appear laminated to S portions of the first panel member;
7 Fig. 16 is a fragmentary perspective vLew of portions of the mold first shown in Fig. 4, and further illustrating 9 portions of the rQold being cle2ned;
1 I Fig. 17 i5 a fragmentary perspective view very similar 1~ to the Viw of Fig. 1 6, and furl~ler ill~u-strating a plurality 13 layers disposed proximate thereto with a substance being 14 applied thereon;
1~
16 Fig. 18 is a reduced perspective vlew of a bucket with 17 a substance being dlsposed therein; =
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19 Fig. 19 is a partial exploded perspective view of the instant invention as it ~ould appear during construction;
22 Fig. 20 is a ~-educed perspective view of the instant 23 invention very similar to the view of Fig. 19, and fu~ther 24 illustrating the instant invention as it would appear disposed proximate a clamp mechanism;
ll Fig. ~l is an enlarged fragmentary perspective view of 2 a plurality of opposing panel members being laminated 3 together;
S Fig. 22 is a reducÆd fragmentary perspettive view very 6 similar to the view of Fig. 21; and 8 Fig. 23 is a reducecl ~ragmentary perspective view of 9 two of the embodiments of the instant inver.tion being joined together.
3 Turning now to the drawings, in which like reference 4 characters indicate corresponding elements throughout the S several views, attention is first directed to Fig. l which 6 illustrates a first embodiment of the instant in~ention 7 comprising a panel being generally designated by t~le g referer~ce char2cter- 30 . he panel 30 illustrated may be 9 used for constructing a selected structure as- desired e.g.
a house, the bod-,y of car, mobile home, motor home, or 11 other si~TIilar type structure as desired, details of which 12 will be described as the ~etailed description ensues. The 1, panel 3~ includes a generally pl2nar first panel member 31, 14 a generally planar second panel merber 32 spaced apart from the first parel rie~ber 31, and an ~nsulating substance 33 16 disposed thereb2twee-. .~lso ircluded is a first reinforcin~
17 element 3q, and a second reinforcing eleIrLent 35, disposed 1~ within tlle ~ nsulating substance 33 and intermediate the l9 first panel member 31 ~ and the second panel member 3~ .
Details of the construction and t~le materiais used in 21 construction of the panel 30 will be presented shortly as 22 the detailed description continues.
1, 2~81407 Reference is no~ directed-to Fig 2, which iLlustrates 2 a detailed view of first panel member 3~1 As can be seen 3 from the above referenced illustration, and consistent with 4 the preferred er;bodiment thereof, first panel member- 31 5 includes a plurality of superimposed layers of one or more 6 materials th2t have been firmly united by an adhesive, 7 resin, or other means to form a substantially rigid and 8 substantially plcnar first panel member- 3L. Specifically, 9 first panel member 31 inrcludes an outer~= layer 90 h2ving 10 exterior surface 40i', and an inner layer 41 spaced apart Il from outer layer ql, and a plurality of intermediate layers 12 residing therebet~een The plurality of lntermediate layers ~ preferably include a first lntermediate ~la~er 42 secured to 14 outer layer 40, a second intermediate layer 43 secured to 15 first intermediate layer 97, a third ir;termediate layer 44 16 secured to secor.d intermediate layer 43, and a fourth ~ intermediate layer ~5 secured to the third intermediate 18 layer q4 and the inner layer 41 T~le outer layer 40 is 19 preferably construc~ed of :a gelcoat materiaI having a 20 selected and precetermined ~hic};ness ~The inner layer 41 21 and the first intermediat~ layer 42 are ~oth preferably 72 constructed of a 10 ounce ~ C~:LTM cloth material, a 2, material thzt is well kno~in to those having skill in the 24 ~ rt 'h - 5 . conc i ~ t e -me d ~ a e ` aye r 4 3 ~nd th e f GUL th intermediate layer 45 are=both preferably constructed of a 7 3/4 Qunce 1~7 mat materizl, another materi21 well known to 3 those having skil~ in the art. Finally, the third 4 intermediate layer 44 is preferably constructed of S ~ U~;TM 2M, and yet still another~material well known 6 to those having skill in ~he art. The various matzrials 7 herein described and used in combinatlon with first panel S member 31 are the preferred materials that when combined 9 together, function to produce a strong, resilient, and light first panel member 31. It will be readily appreciated by I those having ordinary s7~ill that other materials may be used 7 to construct first panel me~ber 31 as desired. For l3 instance, instead of using ~llhl~;~.:Ul:~:TM 2m for the third l4 intermediate layer, coremat or honeycomb may be used. Also, IS instead of using 3/4 ounce 127 mat for the second l6 intermediate layer 43 znd the fourth intermediate layer 4S, 77 ~OEVT~T~, uni-directional fiberglass cloth, heavier mat, or l`3 carbon fiber can be used. Additionally, instead of using 10 19 ounce HEXCELTM cloth for t7~e inner layer 41 and t71e first 20 intermediat~ layer 72, KEVl:,ART~, uni-directional fiberglass 21 cloth, heavier mat, or carbon fiber may be used.
22 Additionally, the first panel member 31 may suitably be 23 constructed of steel or aluminum, a selected plastic 74 substance, acrylic, polyurethane, or any other substance tha~ is s-ubst2ntially rigic', relatively Iight, and resistant 2 to corrosion and decay. Furt}lermore, the details of the 3 constructlon of first par-l member 31, li~-e other portions 4 of panel 30, will be 3.erein described as the detailed 5 description of the preferre:d embodiment continues 6 Attention is no~ dirGcted to Fig. 3, ~lhic~1 illustrates 7 second panel me.~ber 32 ~ike first panel member 31, second S panel member includes a plurality o~ superimposed layers of 9 one or more materials tha. have been firmly united by an adhesive, resin, or othe~ means to form a substantially I l rigid and subst~ntially ]?12nar second panel member 32 .
12 Specifically, secord ?ane l member 32 includes an outermost 13 layer 51 an = innermost layer 51 spaced apart fLom the 14 outermost layer 50, and _ intermediate layer 52 disposed therebetween at an lnterme-~iate position and secured to the l6 outermost layer 50 and the innermost layer 51 ~ith respect 17 to the preferred enbodimer., the outermost layer 'O and the 18 innermost layer 51 are constructed of 10 ounce Hexcel(~3 ~9 cloth material Additionally, the intermediate layer 52 is ~O preferably constructed of 3/4 ounce 1~7 mat material The 2I various materials herein cescribed and .used in combination 22 with second panel me}~ber 32 are the preferred materials that 23 when combined tGsether, f~nction to produce a strong, 24 resilient, and light sec~rd panel member 32_ It will be ~1814Q7 readily appreciated by those having ordinar~J skill that 2 other materials, e.g. those described above in 3 combination with first pcnel member 31, may be used to 4 construct second panel me~ber 32 as desired. Furthermore, S the details of t~e constr~ctlon of second panel merl~ber 32, 6 like further portions of, anel 30, will be herein described 7 as the detailed descriptlon of the preferred embodiment g continues.
A detailed discussion will now commence relating the I l manufacture of panel 30 first depicted in combination with ~ Fig. 1. Turning to Fig. q and Fig. 5, illustrated is a 1~ mold, generally designate by the reference character 55, for 14 use in the manufacture of first par~el member 31 and second 15 panel me~ber 32. As ca~ be seen, mold 55 includes a 36 substantially flat bottGm panel 56 ~aving two upwardly 17 extending end walls, 57 and 58, and two upwardly extending ]g sidewalls, 59 and 60, cll of which termlnate with a 19 laterally extending contlnuous ri.m 61 having an upper ~0 surface 61A. The bottom panel includes a substantially 21 planar -upper sur~ace 56A. Each end wall, 57 and 58, '72 includes an iffffer surfàce, 57A and 58A respectively, and 2~ each side~ all, 59 and 60, includes ar iffner surface, 59A and 24 60A respectively. ~s can ~e seen, mold 55 is shown as being generally rect2ngular in shape. However, although the 2 preferred embodiment of mold 55 is shown as being -generally 3 rectangular, any preferred shape of mold may be used in 4 combination with the manufacture of :panel 30 as may be 5 suitably desired. ~:owever, since the mold 55 is shown as 6 being generally rectangula-, the panel 30 illustrated in 7 combination with the preferred embodiment of panel 30 shown S in Fig. 1 is alsQ generaily rectangular in shape The mold 9 55 may be fabricated of any preferred material e.g.
10 plastic, metal, or other like substance as suitably desired.
l l ~2 With continuing refercnce t~ Fig. 9, prior to using the l3 mold 55 fDr constructing p;~nei 30, it is desLrable to first 14 wash portions of the mold 55 to free debris and foreign 15 matter therefrom so as not to contaminate or discolor 16 p~rtions of paneL 30 whic}l contact mold 55 during 17 construction. Although mold ;5 may be ~ashed by means of IS any preferred . and suitable method, Fig. 4 illustrates a 19 human hand 70 scrubbing an~ washing the upper surface 56A of 20 mold 55 w ith a sponge 71. In'order to effectively wash the 21 upper surface 56A of mold 55, it is normally necessary to 22 use water and a conventional non-abrasive cleanser in 23 comblnation with sponge 71 to properly remove unwanted 24 debris, dirt, and other fQreign matter. After washing the ]S
~ 21 814Q7 mold 55, one of ordinar~ s};ill in the art will re2dily 7 understand that the mold 55 would of course need to be 3 rinsed with Jater to rinse away t~le soap and other debris 4 loosened. through w2shing, 2nd then air dried or manually S dried with a soft chamols or: cloth. Although only upper 6 surface 56A is shown herei n 2s being cleaned, it will be 7 re2dily understood til2t inner surf2ces -57A, 58A, 59A, 6GA, 8 2nd upper surf2ce 61A should 21so be. cleaned in much the 9 same m2nner 2s herein spec~ fically described. Alt~lough not 2bsolutely necess2r~y, it ~ay~ 2~1so be adv2nt2geous to W2X
Il upper surfaces 56A cnd 61~, and ïnner. surfaces 57A, 58A, 7 59A, 2nd 60A, with 2 cDnventional wax sQ . that once .portions 13 of p2nel 30 are~ormed .in. m41d 55, those portions of the 4 panel 30 m2y be e-^~sily remo-~ed therefrom.
16 rlith respect to the m2nuf2c.ture of first p2nel member 17 31, reference is now directed to Fig. 5 which lllustr2tes 2 18 convention21 spr2y gun, det2ils of which 2re well known to 19 those h2ving ordin2ry s~:ill in the 2rt 2nd will not be herein specifically described. The spr2y gun, being 71 generally ~esign2ted by the reference char2cter 72, is shown 77 spraying a substance 73 .up~n portions of upper surf2ce. 56A, 73 61A, 2nd: inner surf2ce 5~. Prefer2bly, substance 73 ls 74 comprised of a conven.tional gelco2t subs~2nce e.g. 2 flex . .
white sanding gelcoat, that needs to be evenly applied to 2 upper surfaces 56A and 61.~, and inner surfaces 57A, 58A, 3 59A, and 60A. PreferabL~, substance 73 is sprayed upon the 4 herein described portions of mold 55 to ensure an even S distribution of substance 73 thereon to achieve a 6 predetermined and selected thickness. :~lowever, substance 73 7 may be applled to the herein described portions of mold 55 8 by means of any preferred method as desired such as 9 spreading. .~fter the substance 73 has been evenly applied lO to achie~Je a predetermined thickness upon the herein I l described portions of mold 55, it must then be left to dry l2 for a sufficien.t arLount of time for the tackiness or l3 sticl~ines-s t~ subside. This layer of substance 73 comprises 14 outer layer 40 o~ first panel member 31.
l6 Attention is now directed to Fig. 6, Fig. 7, and F'g.
17 8, which illust~ate the subsequent steps in the construction IS of first panel me~.ber 31. Essentially, the construction of 19 first paneI membcr 31 illcludes firmly uniting a plurality of 70 superimposed layers of one Dr more selected materials by 21 impregnating the layers with a bonding subst~ance or adheslve 72 e.g. a selected type of resin, that when ultimately cured 23 or dried, forms a substantially rigid and generallY planar 74 panel having a predetermined thicliness. As can be seen in '~O
21814~
Fig. 6, = shown are ~ two hands, 7~ and 77, placing and 2 distributing first inter.~.e~iate layer 42 upon outer layer q0 disposed . upon the upper su~iace 56~. (not herein specifically 4 shown) of bottorn panel 55 of mold 55. Once first S intermedlate layer 41 is :~. place as herein described, Fig.
6 7 illustrates a conventional spray sun, belns generally 7 designated by the refere~ce: character 78, detalls of which 8 will not be herein ~lescri ed as tonventional spray guns are 9 well l~nown, spraying a substance 79 upon portions of surface 80 of first lntermediate 12~Yer 42. Preferably, as h2s been Il intimated herein, su~stance 79 is comprised of a low profile l7 resin, that when 2pslied _o first illtermediate layer q2 by 13 means of .the spra~ sun 79 or by spreading the substance 79 1~ with a trowel 81 e.g. :c~eld by hand ~2, or by means of 15 another suitable met~od, s2.urates and impregnates the first 16 intermediate layer 42 .;~ th .he substance 79, thereby 17 wetting-up first l~}ermedi2te la;/er 4 1~
19 With reference direc~d to ~ig. 8, w~ich illustra.es ~0 how substance 79 may ~e ap71ied ~ ith rolier 83, this process 21 is repeated for the second intermediate layer 43, the third 27 intermediate layer 44, the fourth intermediate layer 45, and 2, finally the inner lay~er ql. Once coInplete, the first panel 24 member 31 is formed, of which can be seen in Fig. 9 showing 7l 21814~7 all of the above referenced layers, 2nd must he left to set 2 up, cure ~r dry, after which it becomes suhstantially rigid, 3 generall ,/ planar, strong, durahle, and lightweight, and which may then b2 easily removed from mold 55 Suhstance 5 79, which is preferably t~!e herein referenced low profile 6 resin, functions as a hording means or- adhesive means for 7 honding the outer lcyer 40 to the first intermediate layer 42, for hond~ng the first intermediate layer 42 to the g second intermedi2te layer 43, for honding the secQnd 10 intermediate layer 43 to the third intermediate layer 9q, Il for honding the third intermediate layer 44 to the fourth 1 ' intermediate layer ~ 45, and for honding the fourth 13 intermedlate layer to the inner layer 41, thereby for~.ing a 1~ plurality~ of superlm?osed and firmly united layers.
~6 Attention is noil directed to Fig. 10 v~hich illustrates 17 a first elongatc~ reinforcing ri~b 90 znd a second elongate 1~ reinforcing rib 91 secured to portions of interior surface 19 40B of first panel member 40, the construction of which ~as been here1n speclflcally desc~ibed. Preferahly constructed 21 of a conventional fozm s~strate, each reinfQrcing rih, 90 22 and 91, includes a lower surface, 90A and 91A respectively, 23 a first side surface, 90B and 91B respectively, a second 24 side surface, 90C and 91C respectively, and an upper 7'1 2~814Q7 . .
surf2ce, 9OD and 511~ recpecti~ely. The first and secDnd 2 reinforcing ribs, O and 91, are preferably spaced apart 3 from one another a predetermined and selected distance, 4 preferably two ~2) fe~t on center, and further dlsposed in a S generally parallel configuration in relation to one another 6 upon interlor surface 90B of first panel rrember 31.
7 With reference to Fig. 11, each reinforcing rib, 90 and g 91, is preferably secured to interior surface 40A by means 9 of an adhesive substance. For instance, as can be seen in Fig. 11, a conventlonal~ hot melt glue gun being generally Il designated by the reference character 95 2nd further being ~2 well known in the prior art, is sho~Jn ~s it would appear ~3 applying a be2d 9~ of convention.al hot ~nelt glue 6 to l4 portions of interior surface 90B. Once the hot melt glue is lS ~pplied, first reinforcing rib 90 is then disposed in the 16 direction indicated by t",- arrowed line A such that the 17 lower surface 90~ contacts the llot .~elt glue 96 thereby l8 securing first rein.forci~ng rib to interior surface 40B. The 19 second reinforcing rib 91 is secured to the interior surface 40B in much the s2me way as the first reinforcïng rib 90.
21 Tt will be readily cQpreciated by those of ordinary skill, 22 that the first and second reinforcing ribs, 90 and 91, may ''3 be secured to the interior surface 40A Qf the first panel 24 member 31 by means of 2ny preferred and suitable securing '~S means. Furthermore, a-ltllQugh for the purposes of the ~3 ~ ~ 2181407 preferred elrbodiment, two reinforclng ribs h2ve been Z disclosed, it will be readily ullderstood that any nu.r[ber and 3 co~bination of reinforcing ribs may be used in combination 4 wi~h the instant invention as suitably desired.
j 6 Reference is now directed .o Eig. 12, whicll illustrates 7 a strip 98 of~- reinforcinq material positioned proximate 8 reinforcilig rib 9l The strip 98 includes an upoer surface 9 98P, a lower surface 98B, and is preferably constructed of Baltic Birch plywood. The strip 98 is s2cured to 11 reinforcing rib 9l by first applying a bead 99~ of hot melt ]Z glue 96 on the upper surface 9ID. The strip 98 is then 13 disposed in the direction Indicated by the arrowed line B
14 and thereb~ glued in place to form the cGnfiguration depicted in E~ig. 13. It ~lill be readily understood that the 16 hot .melt glue 96 ~erves as a means for securing strip 98 to 17 the upper surface 9lD of reinforcing rib 9l, and that when 1~ secured thereto, the strip 98 substantially covers upper 19 surface 9lD of reinforcing rib 9l along its entire lengt!l.
The strip 98 functions as a~ substantially rigid support 21 means for énhan.cing the structural integrity and rlgidity of 22 the reinforcing rib 9l, a furthér description of which will 23 ensue as the detailed description continues. Although not 24 herein speci~ically ` shown, a strip 99 o~~ reinforcing ~ 21814Q7 material, shown in Fig. 15, similar to strip 98, is also 2 secured to the upper surface 90D of reinforcing rib 90 in 3 eY.actly the same way as strip 98 has been herein descr1bed 4 as being secured to reinforcing rib 91, details of which S will not herein again be further described. It will be 6 readily understood by those having ordinary skill, that 7 although strip 98 has been herein described as being 3 constructed of Baltic Bircll plywood, other materials may 9 suitably be used as a su'cstitute e.g. steel, aluminum 10 e~trusions, plastic material, or other suitable material as I l selectively desirQd which is substantially rigid and 12 resilient. Furthermore, reinforcing rib 90 and reinforcing 13 rib 91 may suitably be construc~ed of not only a foam 14 material as herein descrlbed, e.g- BLUE DOW,~M foam, but 15 also a suitable plas~ic material e.g. a selected plastic 16 material, a type of ~ood, or some other suitable material as 17 selectively desired 19 Attention is now directe~ to Fig. lq, which illustrates 20 reinforcing rib 91 ~aving the ,strip 9S attached thereto and 21 further heing laminated to interior ~surface 40B of first 2~ panel member ~1, t~e lamination being desirable to further ~3 secure. the strip ga to relnforcing rib 91, and to further 24 secure reinforcing rib 91 to surface 40B. The lamination of _S
reinforcing rib 9l ~ith the strip 98 secured thereto to interior surface 40B permanently affixes and secures the 3 aforesaid in place upon in~erior surface 40B. As can be 4 seen, the laminaticn involv~s bonding oE llr.pregnating layer 5 lO0 with a: bonding substance lOl e.g. a selected type of 6 resin or ai:dhesive, ~s can be seen as being applied with a 7 trowel 93, and compressing t~e layer lO0 upon Ihe S reinforcing rib 91, the strip ga, and upon portions of the 9 interior surface 40B, to form a laminate layer. Alt~lough 10 any preferred material may l:,e used, layer lO0 is preferably I l comprised of at least two layers = of uni-directional 7 fiberglass cloth that when laminated in place, form two ~3 layers of firmly united material that firmly bond to strip 14 98, reinforcing rib 91, and portions of interior surface 15 qOB. Resins or adhesives suitable for use ~in lamination may 16 comprise a low prGfi le resin, polyurea resln, an epoxy, a 17 polyester resln, o~ other suitable lesin or bonding ~S substance or adhesive~
Fig. 15 illustrates how ,reinforcing rib 9l with the 21 strip 98 secured thereto, and how reinforcing rib 90 with 77 strip 99 secured t~.ereto, appear after lamination has taken 23 place, ~thereby forming reinforcing element 34 and 74 reinforcing element 35, res~ectively, as herein first 7~j . .
disclosed in cor[bination with Fig l. It will be 2 appreciated that the laml~ation of reinforcing rlb 90 with 3 strip 99 secured thereto is laminated using the same 4 technique and method described in combination with Fig. 19, S and will not herein again be specificall / described. The 6 reinforcing eleme~tst 39 and 35, function as reinforcing 7 means for reinforcing panel 30 w11e1l constructed, and for ?3 adding structural integrit ~ to panel 30. The reinforcing 9 means as herein discussed, is the preferred embodiment, and 10 other reinforcing meahs ~ay suitably ~e used in lieu thereof 11 as desired and suitable . It will be readlly appreclated by 12 those skilled in the art, t!lat any number and comblnation of 13 reinforcIng elements may be used in combination with the 14 instant i~vention as desired. --l6 Attention is no~ directed to Fig. lG and 17 which 17 illustrate~ the construction ol~ the second panel me1nber 32.
13 The second panel mel[bér 32 is constructed in much the same 19 way as the first panel memk~er, and so the specific details 70 of construction, ~hich ha~e i~l'ready been herein described in 21 combination with the first panel mer~ber 31, will not herein 27 be again specifically described in enormous detail, as they 2~ will be readily understoQd. As in the construction of the 24 first panel member 31, the construction of the second panel _7 ~ . 21~ 7 member 32 begins wi~h the washing and waxing of portions of mold 55. As c2n be seen in Fig. 16, human h2nd 104 can be 3 seen w2shing upper surf2ce 56A ~,lit~ a spor.ge 105 :prefer2bly with use of co~ventional s02p 2nd w2ter, or other type of non 2br2sive cle2nser (no, herein specifically shown). Once 6 t}le upper surf2ce 56A h2s been sufficiently cle2ned to 7 remove unw~nted dirt or other foreign debris, the upper 8 surf2ce 56A then prefe~rabIy needs [o be w2xed so th2t when 9 the construction of secol~.d p2nel member 32 is complete, it may be easlly r~mo~ed. hlaxing is ~Jell l;.nown, and the Il details of which will not ~.erein be speclfically addressed.
12 However, as can be seen in Fig. 16, a wax_ng substa~ce 106, 13 of any conventioral and prefl~rred type, can be seen 2s being 14 2pplied to: upper surf2ce . 56.~ by me2ns of spre2ding with 2 trowel 107, and b~ eans of spràying w~th a spray device 16 108. It will be readiLy -opreclateQd th2. waxlng substa~ce 17 106 may bè appli~-d to u~er surface 55~. by means of any IS preferred 2nd suitzble metnocl.
Turning specifically to ,Fig. 17, illustr2ted is the 21 construction of seco:~-d p2nel nember 32. Li~.e first panel 22 member 31, secord p2nel member is prefer2bly comprised o~ a 23 plur21ity of super~ osed layers bonded tQsether with a 24 bonding substance e.g. a selected resin or adhesive.
Specific211y, second panel member 32 includes the outermost 2 layer 50 placed upon upper surface 56.i~, the intermediate layer 52 superi~pos~d upon the outer~ost layer, and the 4 lnnermost layer 51 superi~posed upon tlle intermediate layer 52. Each layer, 50, 51, an.d 52, is impregnated with bonding 6 substance 110 as e2ch is cons2cutively superimposed one atop 7 the other. Bonding substc~ce 110 is preferably comprised of S a low profile r~sin, but m,2y also be comprised of a polyurea 9 resin, an epoxy substance, o-r 2 polyester resin, or any other suitable bonding substance or 2dhesive substance 3l Once the bonding substance 110 cures, sets up, or dries, 1~ second panel member ~32 b~comes substantially rigid having l3 exterior s~Irface 12A c~d interior surface 32B, the 14 configuration of which cGn be seen in -~ig. 19. Bo~.ding substanc~ lI0 may ~e= ap~lied by means of any preferred t6 method e.g. spra~ a, coreading, or rolling e.g. with 17 roller lll as illustrated, or any other preferred method as IS d~sired.
Turning now to Fig. 19, i~rus~rated lS tlle next step in 21 the construction of panel 30. ~s can be seen, a bonding 22 substance 115 is seen as having been disposed on portions of 2~ the upper~ surface, 116 and 117, of each respective 24 reinforcing ~ element, 34 2nd 35 . SeGond panel member 32 is 21814~7 then disposed in the direction ind1cated b~ the 2rrowed line 2 C such that the interior sarface 32B becomes engaged with bonding substance 115, thereby engaging the second panel 4 member 32 to the recpective reinforclng elements, 3q and 35 S respectively, to form the configuratiQn of panel 30 6 illustrated in comoination witl~ Fig. 20. As a res~lt of 7 such a configuration, first par.el memL~er 31 and second panel 8 member 32 are - sp2ced ap2rt from one another such that 9 interior s~lrface 32B and interior surface qOB are spaced in ]0 a di2metrically opposed and spaced apart orientation and in I l a generally planar and generally parallel configuration 12 relative ~to Qne another, thereby forming space: 120 13 therebetween within the 2-ea- encompassed by both interlor 14 surfaces, 32B and 40}.
16 With moment2ry reference to Fig. 18, shown is a bucket 17 125 being filled with a first substance 12~, and a second 18 substance 127 Consistent with the preferred embodiment, 19 substance- 12~ being added to bucl~.et 125 includes the low '0 profile resin previously descrihed hereln, and substance 127 21 being added to bucket 125 includes a substance !~nown as Cab-22 o-sil, which is h~ell l~.nown by those having ordinary skill.
23 The low profiIe resin, which may also be another type of ~4 suitable resin or adhesive substance e.g. polyurea resin, an epoxy, or a polyester resin, and the Cab-o-sil are mixed 2 together~ until the mixture ta}.es on the conslstency of 3 peanut butter. This m.ixture ma~:es up the preferred 4 embodiment of bonding substance 115. ~owever, it will be 5 appreciated by those.havirg o-rdinary skill in the art that 6 other substances having cuitable and adequate bondillg or 7 adhesi~e characteristics may be used in lieu of bonding substance 115 as here~ n specifically descrlbed ln 9 combin2tion wlth Fig. 18 and Flg. l9.
1ith ref~erence again ~lirected to Fig. 20, panel 30 is 12 seen disposed intermediate an upper cl2mp fixture 127 and a 13 lower clamp fixture 128 . Lower cla~p ~lx~ure 1, 8 functions 14 as a clamping base agamst which paneL ~30 rests such that I j when upper clamping fixture 127 is disposed in the direction 16 indicated. by the arrowed lir.e D, the panel 30 becomes l7 clamped therein and ~esides intermediate upper clamp fixture 1~ 127 and lowe~ clamp fixture 128.: ~nce panel 30 is clamped 19 in place, insulatinq substance 33 may then be properly disposed within space 120. ~.s can be seen in Fig. 20, a 2I conventional spray gun is shown spraying insulating 22 substance . 33 into space 12Q _ The insuLating substance 33 is 23 pre-ferably comprised of an eYpandable polyurethane foam that ~4 wher sprayed ihto s~ace 17i,~pends t~ sub~tentially iill space 120. Since insulatlng substance ~33 is preferably an 2 expand2ble fo2m substance, p2nel 30 must be clamped down so 3 th2t p2nel 30 coes IlOt bre2k 2p2rt 2s 2 result of the 4 lntern21 pressure exerted by the i~02m as it expands within S sp2ce 120. Any preferreci me2ns Qf cl2mplng, e-g- th2t 6 herein specific211y descr~bed in rel2tion to the preferred 7 embodi.ment, .m2y be used f~r securing or= cl2mping panel 30.
S Although insul2ting subst2!lce 33: h2s been hereln described 9 2s being a pQlyureth2ne fGam, other subst2nces suit2ble for ]0 use with the inst2nt i~vention m2y 21so be used 2s I l selectively desired, 2nd t:~2t the polyureth2ne fo2m has been 12 herein disclose~ merely for th2 purpose . of illustr2tion of l3 the preferred e~rboc!iment. Cnce insul2ting subst2nce 33 14 exp2nds 2nd cures or dr:es, the panel ~0 is complete, lS thereby fo.rming l~.e e~!bodi-ent first illustrated in Fiq. 1.
l7 Turning no~ to Fig. 21:,- sho~Jn 2re two panels, a iS subst2nti211y plæl2r first p2nel 135 h2vinq 2 le2ding edge 19 135A, and 2 substanti211y planar second panel 136 h2ving a le2ding edge 136.~. FQr the purpose of =orient2tion, first 21 panel 135 :znd second panel 136 2re prefer2bly constructed 2' simil2r to: first panel member 31. The purpose of Fig. 21 is 23 to illustrate how portions of first panel 135 and portiQns 4 of panel 136, proxim2te leading edge 135 and leading edge 136 respèctively, may be manuf2ctured to include: a first 2 recessed portion 135B and second recessed portion 136B, 3 respectively As a result of such a configuration, leading 4 edge 135A and leading edge 136A may be brought in S juxtaposition in a diametrlcally opposed configuration and 6 then laminated together, thereby securing first panel 135 to 7 second panel 136 LO create z larger panel section, being g generally designated by the reference chzracter 137.
~lith continuing reference tQ Fig. ~1, and additional Il reference~ to Fig. 2~,: to properly secure first panel 135 to secQnd panel L36, not onIy should first p2nel 135 and second 1~panel 136: be 12mir~ted together by aGpiying a laminate layer ~4proximate first recessed portion 135B 2rd second recessed 15portion 135B, but also pro~iimate the bottGm surfaces (not ]6herein specificall~ s'~Gl~n) of~ the first pan~l 135 and tlle 17second panel 136 directl~y op~osite th~ r~spective first 18 recessed portion 1353 and the second recessed portion 136B.
1~ Like the preferLed laminatiol1 method hereln described in 20combination with Fig. lq, the laminat_on herein involues 2Idisposing a first layer lqO s~ch t~a~ first layer lqO
22overlaps and substantially covers each of the respective 2~ recessed portions, 135B and 135B respectively, superimposing 24 a second layer 141 upon first layer lqO, and impregnating , ~
~ 2181407 the first ~and secQnd layers, 140 and lql, witll bonding 2 substance 142 to bond the layers lq~ and 191 together and to 3 bond the first and second pane-ls, 135 and 136 respectively, 4 together. Although any preferred material may be used, S first layer LqO and ~seco~d layer 191 are preferably 6 comprised of a uni-directLonal flberglass cloth. Al[hough 7 the lamination herein described dlscloses two layers, any 8 number of~ layers may be used in the lamination as suitably 9 desired. The bonding subs;ance 142 suitable for use in the above described lamin2tion may include a low profile resin, I l polyurea resin, 2n epoXy, a polyester~ resin, or othe~
1~ suitable resin, bonding substance, or adhesive.
14 With continuing reference to Fig. 22, once first panel IS 135 and second pcnel 136 ha~e been lzminated together, it is 16 desirable tQ ap~ly a layer of cementing substance 145 on top 17 of the 12mination la~ier disposed Jithi~ lle first recessed 18 portion 135B and the seco~d recessed portion 136B. The Ig cementing substance~ 145 ~ay be applied by use of any preferred. method. IIowever, a' satisfactory way of applying 21 cementing substa~ce 145 is through the use of a trowel 146 22 which can be seen as beillg held by human hand lq7 for ~3 spreading the cement~ng substance lq5 atop the layer of 24 laminate shown. ~lthough any preferred cementing substance 21814~7 lq5 may be used in combiration with the instant invention, 2 it must be resilient and strong when it cures or dries, and 3 may therefore consist of a resilient caulking substance, or 4 a substance referred to as i30ndo,~ a comm.on substànce readily known to those having ordinary skill and typicalLy used for 6 repairin~ external au::omooile parts that have been damaged 7 or compromised_ Once the cementing substance 145 has cured or dried sufficien~ly, it may then be sanded smooth such as 9 with a sanding element 148 ~eld by human hand 149, as can be seen with reference: to Fig. 23. It will be readily I l appreciated in light of t~e foregoing discussion, that two 17 or more panels, such as preferred panel 30 seen in Fig. 1, 13 may be joined together using the method of joining flrst 14 panel 135 and second panel 136 herein discussed in combination with Fig. 21, F:ig. 22, and Fig. 23. However, it 16 will further be ap~7reGiated that in order to join a l7 plurality of panels toge~her, the various panel members must l8 be first: joined together prior to introducing insulating 19 substance 33 theretQ to for~ a completed panel segment, such as panel segment 150 illustrated in Fig. 23, which shows 21 panel ~51 joined to panel ~ 152. It will be readily 22 appreciated by those havin.g ordinary skill that although the 23 above discussion discloses wllat is believed to the preferred 24 method of joining a plurality of panels together, any ` 2181407 preferl~ed and suitcble rnethod ~f joining m2y be used as 2 selectlvely desired.
,6
decorative features.
]
i 2181407 Beglnnlng in the ~0t11 century, a wide varlety of 2 materials came into use in the manufactur~e of paneling. For 3 instance, solld wood e.g. walnut, mahogany, birch, and 4 redwood, became commonplace mzterials fQr the construction S of paneLing. Other materi21s that became useful in the 6 construction of paneling rurther consis.ed of .plywood (a 7 thin wood veneer on a plywood base), vinyl with surface 8 imitating wood grain, hardboard (or pressed wood), pegboard, 9 and even transLucent materials . e.g. ~;UCITE~. ~ith the advent of: technological advances in the construction of 11 automobiles, sea-golng ~-ehicles, airplanes, and space 12 vehicles, = the importance of constructinq paneling resistant 13 to environmental elements, corroslon, and large vari~nces in 14 temperature and pressure became very important for use in constructing such apparatus. ~ For instance, the panellng 16 used in .the - cpnstruction of many aerospace vehicles is 17 typically corstructed of hiqh impact, heat resistart ceramlc 18 composite: substances .
~9 Prefabricated panellng can be used for constructing an 21 array structures e.g. housés, cars, motor-homes, mobile-22 homes, planes, and other similar structures. It will be 23 readily appreciated that paneling used for the construction 24 of such structures needs to have high insulating characterlstics fol~ res' sting larSIe variances in -. 2~814Q7 temperature, and also r.eeds to be possess sufficient 2 strength in order to be resist2nt to dam2ge resulting from 3 impact and to provide structural integrity. However, most 4 paneling that is both strong while having good insulating S characteristics, is heavy. As a consequence, there is a 6 need to produce.paneling for use in constructing a structure 7 that is not only strong, resi~lien~, and a good insulator, but also light so that structures may be easily constructed.
It would be highly advantageous, therefore, to remedy 11 the foregoing and other~ ~eficiencies i~herent in the prior 12 art.
14 AccordingIy, it is an object of the present invention 15 to provide a new ~nd useful panel for use in constructing a 16 selected structure.
1~3 Another objcct of the present invelltion is to provide a 19 panel that is strorg.
21 ~nother obj ect of ~the present invention lS to 22 provide a panel thât is light.
. 21814Q7 Still another object of the present inYention is to 2 provide a panel th2t is ~ a good insul2tor ag2inst large 3 variations in temperature.
Yet another object of the instant invention is to 6 provide 2 p2nel th2t may be used for constructing motor-7 homes znd the like.
9 Yet still a~other object of the instznt invention is to provide z pznel thzt is ezsy znd inexpensive tq mznufzcture 12 Yet a further object of .he invention is to provide z 13 panel thzt is resistant to breakage. -Still a further object of the immediate invention is to 16 provide a pallel that is resistant tq the deteriorating 17 affects qf oxygen, water ~-auid or vapor, salts, znd other 18 environmental elements.
Yet z further obj ect of the invention is to provide z 21 new znd useful method of const,ructing z pznel.
23 Still z further obj ect of the invention is to 24 provide z new znd useful method of joining z plurality of ~5 pa~els togeth4~.
. . 21814~7 Yet still a further object of the invention is to '~ provide a: panel that is easy to repair. - -3 Briefly, to achieve the desired sbjects of the instant 4 invention in-accordance with a preferred embodiment thereof, provided is a panel for~ use in constructing a structure or 6 architecture, a method of manufacturing a panel, and a 7 method of joining a plurality of panel memlsers. The panel 8 includes a substantially rigid generally planar first panel 9 member and a substantially rigid generally planar second panel me.~ber spaced apart '~rom and generally parallel to the 11 first panel member thereby creating a space therebetween.
12 Disposed.intermediate the first paneI member and the second 13 panel member proximate the space exist an insulating 14 substance substantially fl!ling the space and a reinforcing means comprising a plurality of reinforcing elements for 16 adding structural integrity and strength to t1le panel.
1~
18 The method of manufacturing a panel includes the steps 19 of providing a substantially rigid generally planar first panel member and 2 substantially rigid generally planar 21 second panel member spaced~~apa~rt from and generally parallel 22 to the first panel member ~ thereby creating a space 23 therebetween. The step of providing the first panel memoer 24 includes the steps of superimposing a plurality of layers of 25 material, and firmly uniting the plurality of layers of ~ . 2~81437 material together wlth a bonding substance. Furthermore, 2 the step of providing t~le second panel member likewise 3 includes the steps of firn~ly uniting a~ pluraIity of layers 4 of material together with a bondil~g substance. ~he next S step involves Introducing reinforcing means proximate the 6 space for adding structural~ integrity and strength to the 7 panel, and then substanti ally filling the space with an 8 insulating substance.
The method of joining a plurality of panel members Il includes the steps of providing a substantially planar firs~c 17 panel and a substantially planar second panel, providing a 13 first recessed portion proximate the first panel and 14 providing a second recessed portion proYimate the second 15 panel, juxtaposing the first recessed portion proximate the 16 second recessed portion, and securing the first panel and 17 the second panel together by preferably disposing lamination 1S proximate the first and second recessed portions to form a 19 substantially planar panel ~se~tion.
In the accompanying drawings:
9 Flg. 1 is a perspecti~e view of an,, eml~odiment of the instant invention constructed ln accordance with the II preferred embodimenti 13 Fig. 2 is an enlarged fragmentary perspective view of ,,, 4 po~tions of the e~od~, m.ent ~eplcted in Fig . 1;
16 Fig. 3 is a vie~1 very similar to the view of Fiq. 2;
18 Fig. 4 is a fra~mentary perspective view ,of a mold ~or 19 use in constructing the embodiment depicted in Fig. l, and further illustrating a human hand holding a cleaning device, 21 for use in cleaning portions o~ ~he mold as showni 23 Fig. 5 is a perspective view of the entire mold first 24 shown in combination ', ith Fig. 4, and further illustrating a 21~1407 spraylng device spraylng ~ a substance upon portions of the 2 mold;
4 Fig. 6 is a perspecti~e view of a pair of human hands S applying a layer ~or use in constructiDn of the embodiment 6 shown in Fig. 1, and furtrler showing the layer as it would 7 appear being disposed upon portions of the mold depicted in 8 Fig. 5;
Fig. 7 is a perspec'ive view very~ similar to the view I ] of Fig. 6, and further il lustrating a spray device spraying 7a substance upon portions - of the layer, and a human hand ~3holding a sErreading device for spreading a substance upon 14portions of the layer;
16 Fig. a is a perspect~ ve view very similar to the view 17 of Fig. ~, and ~urther lllustrating a roller device 18spreading a substance upor another layer superimposed atop 19the layer first illustrated in Fig. 6;
~ Fig. 9 is an enl~rged fragmentary side elevational view 22 of a first panel member of the instant invention as first 23shown in Fig. 2;
2~1407 Fig. lO is a ~ront eleva[ional view oi pGrtio11s of the 2 instant invention as- illustrated during construction o~ the 3 embodlment depicted in Fig. l, and further illustrating a 4 plurality of reinforcing ~lbs positioned upon portions of S the first panel meri~er;
7 Fig. ll is a perspectlve view~ very similar to the view g o Fig. 10, and further illustrating one of the pluraIity of 9 reinforcing ribs being secured to portions of the first ]O panel member; ~ -Il ]2 Fig. 1'7 `i5 an e~large~ fra~entary perspective vie~ of ]3 one of the plurality of reinforcing ribs as shown, and ~4 further having a strip of reinforcirlg material applied thereto; _ .
17 Fig. 13 i5 cn enlarged fragmentary front 1g elevational view o. portions of the instant: lnvention ]9 illustrating one of the plurality of reinforcing ribs with ~0 the strip of reinforclng material secured thereto;
2]
22 Fig. 14 is an enlarged fragmentary perspective view of ~, one of the plurality of reinfDrcing ribs being laminated to 24 portions of the first panel member;
]O
] Fig. 15 lS an enl2rged ~ragmentary ~ront elevational 2 view of portions of the lnstant invention, very similar to 3 the view of Fig. 10, and f~lrther~ illustrating the plu~ali.y 4 of reinforcing ribs as they would appear laminated to S portions of the first panel member;
7 Fig. 16 is a fragmentary perspective vLew of portions of the mold first shown in Fig. 4, and further illustrating 9 portions of the rQold being cle2ned;
1 I Fig. 17 i5 a fragmentary perspective view very similar 1~ to the Viw of Fig. 1 6, and furl~ler ill~u-strating a plurality 13 layers disposed proximate thereto with a substance being 14 applied thereon;
1~
16 Fig. 18 is a reduced perspective vlew of a bucket with 17 a substance being dlsposed therein; =
1~
19 Fig. 19 is a partial exploded perspective view of the instant invention as it ~ould appear during construction;
22 Fig. 20 is a ~-educed perspective view of the instant 23 invention very similar to the view of Fig. 19, and fu~ther 24 illustrating the instant invention as it would appear disposed proximate a clamp mechanism;
ll Fig. ~l is an enlarged fragmentary perspective view of 2 a plurality of opposing panel members being laminated 3 together;
S Fig. 22 is a reducÆd fragmentary perspettive view very 6 similar to the view of Fig. 21; and 8 Fig. 23 is a reducecl ~ragmentary perspective view of 9 two of the embodiments of the instant inver.tion being joined together.
3 Turning now to the drawings, in which like reference 4 characters indicate corresponding elements throughout the S several views, attention is first directed to Fig. l which 6 illustrates a first embodiment of the instant in~ention 7 comprising a panel being generally designated by t~le g referer~ce char2cter- 30 . he panel 30 illustrated may be 9 used for constructing a selected structure as- desired e.g.
a house, the bod-,y of car, mobile home, motor home, or 11 other si~TIilar type structure as desired, details of which 12 will be described as the ~etailed description ensues. The 1, panel 3~ includes a generally pl2nar first panel member 31, 14 a generally planar second panel merber 32 spaced apart from the first parel rie~ber 31, and an ~nsulating substance 33 16 disposed thereb2twee-. .~lso ircluded is a first reinforcin~
17 element 3q, and a second reinforcing eleIrLent 35, disposed 1~ within tlle ~ nsulating substance 33 and intermediate the l9 first panel member 31 ~ and the second panel member 3~ .
Details of the construction and t~le materiais used in 21 construction of the panel 30 will be presented shortly as 22 the detailed description continues.
1, 2~81407 Reference is no~ directed-to Fig 2, which iLlustrates 2 a detailed view of first panel member 3~1 As can be seen 3 from the above referenced illustration, and consistent with 4 the preferred er;bodiment thereof, first panel member- 31 5 includes a plurality of superimposed layers of one or more 6 materials th2t have been firmly united by an adhesive, 7 resin, or other means to form a substantially rigid and 8 substantially plcnar first panel member- 3L. Specifically, 9 first panel member 31 inrcludes an outer~= layer 90 h2ving 10 exterior surface 40i', and an inner layer 41 spaced apart Il from outer layer ql, and a plurality of intermediate layers 12 residing therebet~een The plurality of lntermediate layers ~ preferably include a first lntermediate ~la~er 42 secured to 14 outer layer 40, a second intermediate layer 43 secured to 15 first intermediate layer 97, a third ir;termediate layer 44 16 secured to secor.d intermediate layer 43, and a fourth ~ intermediate layer ~5 secured to the third intermediate 18 layer q4 and the inner layer 41 T~le outer layer 40 is 19 preferably construc~ed of :a gelcoat materiaI having a 20 selected and precetermined ~hic};ness ~The inner layer 41 21 and the first intermediat~ layer 42 are ~oth preferably 72 constructed of a 10 ounce ~ C~:LTM cloth material, a 2, material thzt is well kno~in to those having skill in the 24 ~ rt 'h - 5 . conc i ~ t e -me d ~ a e ` aye r 4 3 ~nd th e f GUL th intermediate layer 45 are=both preferably constructed of a 7 3/4 Qunce 1~7 mat materizl, another materi21 well known to 3 those having skil~ in the art. Finally, the third 4 intermediate layer 44 is preferably constructed of S ~ U~;TM 2M, and yet still another~material well known 6 to those having skill in ~he art. The various matzrials 7 herein described and used in combinatlon with first panel S member 31 are the preferred materials that when combined 9 together, function to produce a strong, resilient, and light first panel member 31. It will be readily appreciated by I those having ordinary s7~ill that other materials may be used 7 to construct first panel me~ber 31 as desired. For l3 instance, instead of using ~llhl~;~.:Ul:~:TM 2m for the third l4 intermediate layer, coremat or honeycomb may be used. Also, IS instead of using 3/4 ounce 127 mat for the second l6 intermediate layer 43 znd the fourth intermediate layer 4S, 77 ~OEVT~T~, uni-directional fiberglass cloth, heavier mat, or l`3 carbon fiber can be used. Additionally, instead of using 10 19 ounce HEXCELTM cloth for t7~e inner layer 41 and t71e first 20 intermediat~ layer 72, KEVl:,ART~, uni-directional fiberglass 21 cloth, heavier mat, or carbon fiber may be used.
22 Additionally, the first panel member 31 may suitably be 23 constructed of steel or aluminum, a selected plastic 74 substance, acrylic, polyurethane, or any other substance tha~ is s-ubst2ntially rigic', relatively Iight, and resistant 2 to corrosion and decay. Furt}lermore, the details of the 3 constructlon of first par-l member 31, li~-e other portions 4 of panel 30, will be 3.erein described as the detailed 5 description of the preferre:d embodiment continues 6 Attention is no~ dirGcted to Fig. 3, ~lhic~1 illustrates 7 second panel me.~ber 32 ~ike first panel member 31, second S panel member includes a plurality o~ superimposed layers of 9 one or more materials tha. have been firmly united by an adhesive, resin, or othe~ means to form a substantially I l rigid and subst~ntially ]?12nar second panel member 32 .
12 Specifically, secord ?ane l member 32 includes an outermost 13 layer 51 an = innermost layer 51 spaced apart fLom the 14 outermost layer 50, and _ intermediate layer 52 disposed therebetween at an lnterme-~iate position and secured to the l6 outermost layer 50 and the innermost layer 51 ~ith respect 17 to the preferred enbodimer., the outermost layer 'O and the 18 innermost layer 51 are constructed of 10 ounce Hexcel(~3 ~9 cloth material Additionally, the intermediate layer 52 is ~O preferably constructed of 3/4 ounce 1~7 mat material The 2I various materials herein cescribed and .used in combination 22 with second panel me}~ber 32 are the preferred materials that 23 when combined tGsether, f~nction to produce a strong, 24 resilient, and light sec~rd panel member 32_ It will be ~1814Q7 readily appreciated by those having ordinar~J skill that 2 other materials, e.g. those described above in 3 combination with first pcnel member 31, may be used to 4 construct second panel me~ber 32 as desired. Furthermore, S the details of t~e constr~ctlon of second panel merl~ber 32, 6 like further portions of, anel 30, will be herein described 7 as the detailed descriptlon of the preferred embodiment g continues.
A detailed discussion will now commence relating the I l manufacture of panel 30 first depicted in combination with ~ Fig. 1. Turning to Fig. q and Fig. 5, illustrated is a 1~ mold, generally designate by the reference character 55, for 14 use in the manufacture of first par~el member 31 and second 15 panel me~ber 32. As ca~ be seen, mold 55 includes a 36 substantially flat bottGm panel 56 ~aving two upwardly 17 extending end walls, 57 and 58, and two upwardly extending ]g sidewalls, 59 and 60, cll of which termlnate with a 19 laterally extending contlnuous ri.m 61 having an upper ~0 surface 61A. The bottom panel includes a substantially 21 planar -upper sur~ace 56A. Each end wall, 57 and 58, '72 includes an iffffer surfàce, 57A and 58A respectively, and 2~ each side~ all, 59 and 60, includes ar iffner surface, 59A and 24 60A respectively. ~s can ~e seen, mold 55 is shown as being generally rect2ngular in shape. However, although the 2 preferred embodiment of mold 55 is shown as being -generally 3 rectangular, any preferred shape of mold may be used in 4 combination with the manufacture of :panel 30 as may be 5 suitably desired. ~:owever, since the mold 55 is shown as 6 being generally rectangula-, the panel 30 illustrated in 7 combination with the preferred embodiment of panel 30 shown S in Fig. 1 is alsQ generaily rectangular in shape The mold 9 55 may be fabricated of any preferred material e.g.
10 plastic, metal, or other like substance as suitably desired.
l l ~2 With continuing refercnce t~ Fig. 9, prior to using the l3 mold 55 fDr constructing p;~nei 30, it is desLrable to first 14 wash portions of the mold 55 to free debris and foreign 15 matter therefrom so as not to contaminate or discolor 16 p~rtions of paneL 30 whic}l contact mold 55 during 17 construction. Although mold ;5 may be ~ashed by means of IS any preferred . and suitable method, Fig. 4 illustrates a 19 human hand 70 scrubbing an~ washing the upper surface 56A of 20 mold 55 w ith a sponge 71. In'order to effectively wash the 21 upper surface 56A of mold 55, it is normally necessary to 22 use water and a conventional non-abrasive cleanser in 23 comblnation with sponge 71 to properly remove unwanted 24 debris, dirt, and other fQreign matter. After washing the ]S
~ 21 814Q7 mold 55, one of ordinar~ s};ill in the art will re2dily 7 understand that the mold 55 would of course need to be 3 rinsed with Jater to rinse away t~le soap and other debris 4 loosened. through w2shing, 2nd then air dried or manually S dried with a soft chamols or: cloth. Although only upper 6 surface 56A is shown herei n 2s being cleaned, it will be 7 re2dily understood til2t inner surf2ces -57A, 58A, 59A, 6GA, 8 2nd upper surf2ce 61A should 21so be. cleaned in much the 9 same m2nner 2s herein spec~ fically described. Alt~lough not 2bsolutely necess2r~y, it ~ay~ 2~1so be adv2nt2geous to W2X
Il upper surfaces 56A cnd 61~, and ïnner. surfaces 57A, 58A, 7 59A, 2nd 60A, with 2 cDnventional wax sQ . that once .portions 13 of p2nel 30 are~ormed .in. m41d 55, those portions of the 4 panel 30 m2y be e-^~sily remo-~ed therefrom.
16 rlith respect to the m2nuf2c.ture of first p2nel member 17 31, reference is now directed to Fig. 5 which lllustr2tes 2 18 convention21 spr2y gun, det2ils of which 2re well known to 19 those h2ving ordin2ry s~:ill in the 2rt 2nd will not be herein specifically described. The spr2y gun, being 71 generally ~esign2ted by the reference char2cter 72, is shown 77 spraying a substance 73 .up~n portions of upper surf2ce. 56A, 73 61A, 2nd: inner surf2ce 5~. Prefer2bly, substance 73 ls 74 comprised of a conven.tional gelco2t subs~2nce e.g. 2 flex . .
white sanding gelcoat, that needs to be evenly applied to 2 upper surfaces 56A and 61.~, and inner surfaces 57A, 58A, 3 59A, and 60A. PreferabL~, substance 73 is sprayed upon the 4 herein described portions of mold 55 to ensure an even S distribution of substance 73 thereon to achieve a 6 predetermined and selected thickness. :~lowever, substance 73 7 may be applled to the herein described portions of mold 55 8 by means of any preferred method as desired such as 9 spreading. .~fter the substance 73 has been evenly applied lO to achie~Je a predetermined thickness upon the herein I l described portions of mold 55, it must then be left to dry l2 for a sufficien.t arLount of time for the tackiness or l3 sticl~ines-s t~ subside. This layer of substance 73 comprises 14 outer layer 40 o~ first panel member 31.
l6 Attention is now directed to Fig. 6, Fig. 7, and F'g.
17 8, which illust~ate the subsequent steps in the construction IS of first panel me~.ber 31. Essentially, the construction of 19 first paneI membcr 31 illcludes firmly uniting a plurality of 70 superimposed layers of one Dr more selected materials by 21 impregnating the layers with a bonding subst~ance or adheslve 72 e.g. a selected type of resin, that when ultimately cured 23 or dried, forms a substantially rigid and generallY planar 74 panel having a predetermined thicliness. As can be seen in '~O
21814~
Fig. 6, = shown are ~ two hands, 7~ and 77, placing and 2 distributing first inter.~.e~iate layer 42 upon outer layer q0 disposed . upon the upper su~iace 56~. (not herein specifically 4 shown) of bottorn panel 55 of mold 55. Once first S intermedlate layer 41 is :~. place as herein described, Fig.
6 7 illustrates a conventional spray sun, belns generally 7 designated by the refere~ce: character 78, detalls of which 8 will not be herein ~lescri ed as tonventional spray guns are 9 well l~nown, spraying a substance 79 upon portions of surface 80 of first lntermediate 12~Yer 42. Preferably, as h2s been Il intimated herein, su~stance 79 is comprised of a low profile l7 resin, that when 2pslied _o first illtermediate layer q2 by 13 means of .the spra~ sun 79 or by spreading the substance 79 1~ with a trowel 81 e.g. :c~eld by hand ~2, or by means of 15 another suitable met~od, s2.urates and impregnates the first 16 intermediate layer 42 .;~ th .he substance 79, thereby 17 wetting-up first l~}ermedi2te la;/er 4 1~
19 With reference direc~d to ~ig. 8, w~ich illustra.es ~0 how substance 79 may ~e ap71ied ~ ith rolier 83, this process 21 is repeated for the second intermediate layer 43, the third 27 intermediate layer 44, the fourth intermediate layer 45, and 2, finally the inner lay~er ql. Once coInplete, the first panel 24 member 31 is formed, of which can be seen in Fig. 9 showing 7l 21814~7 all of the above referenced layers, 2nd must he left to set 2 up, cure ~r dry, after which it becomes suhstantially rigid, 3 generall ,/ planar, strong, durahle, and lightweight, and which may then b2 easily removed from mold 55 Suhstance 5 79, which is preferably t~!e herein referenced low profile 6 resin, functions as a hording means or- adhesive means for 7 honding the outer lcyer 40 to the first intermediate layer 42, for hond~ng the first intermediate layer 42 to the g second intermedi2te layer 43, for honding the secQnd 10 intermediate layer 43 to the third intermediate layer 9q, Il for honding the third intermediate layer 44 to the fourth 1 ' intermediate layer ~ 45, and for honding the fourth 13 intermedlate layer to the inner layer 41, thereby for~.ing a 1~ plurality~ of superlm?osed and firmly united layers.
~6 Attention is noil directed to Fig. 10 v~hich illustrates 17 a first elongatc~ reinforcing ri~b 90 znd a second elongate 1~ reinforcing rib 91 secured to portions of interior surface 19 40B of first panel member 40, the construction of which ~as been here1n speclflcally desc~ibed. Preferahly constructed 21 of a conventional fozm s~strate, each reinfQrcing rih, 90 22 and 91, includes a lower surface, 90A and 91A respectively, 23 a first side surface, 90B and 91B respectively, a second 24 side surface, 90C and 91C respectively, and an upper 7'1 2~814Q7 . .
surf2ce, 9OD and 511~ recpecti~ely. The first and secDnd 2 reinforcing ribs, O and 91, are preferably spaced apart 3 from one another a predetermined and selected distance, 4 preferably two ~2) fe~t on center, and further dlsposed in a S generally parallel configuration in relation to one another 6 upon interlor surface 90B of first panel rrember 31.
7 With reference to Fig. 11, each reinforcing rib, 90 and g 91, is preferably secured to interior surface 40A by means 9 of an adhesive substance. For instance, as can be seen in Fig. 11, a conventlonal~ hot melt glue gun being generally Il designated by the reference character 95 2nd further being ~2 well known in the prior art, is sho~Jn ~s it would appear ~3 applying a be2d 9~ of convention.al hot ~nelt glue 6 to l4 portions of interior surface 90B. Once the hot melt glue is lS ~pplied, first reinforcing rib 90 is then disposed in the 16 direction indicated by t",- arrowed line A such that the 17 lower surface 90~ contacts the llot .~elt glue 96 thereby l8 securing first rein.forci~ng rib to interior surface 40B. The 19 second reinforcing rib 91 is secured to the interior surface 40B in much the s2me way as the first reinforcïng rib 90.
21 Tt will be readily cQpreciated by those of ordinary skill, 22 that the first and second reinforcing ribs, 90 and 91, may ''3 be secured to the interior surface 40A Qf the first panel 24 member 31 by means of 2ny preferred and suitable securing '~S means. Furthermore, a-ltllQugh for the purposes of the ~3 ~ ~ 2181407 preferred elrbodiment, two reinforclng ribs h2ve been Z disclosed, it will be readily ullderstood that any nu.r[ber and 3 co~bination of reinforcing ribs may be used in combination 4 wi~h the instant invention as suitably desired.
j 6 Reference is now directed .o Eig. 12, whicll illustrates 7 a strip 98 of~- reinforcinq material positioned proximate 8 reinforcilig rib 9l The strip 98 includes an upoer surface 9 98P, a lower surface 98B, and is preferably constructed of Baltic Birch plywood. The strip 98 is s2cured to 11 reinforcing rib 9l by first applying a bead 99~ of hot melt ]Z glue 96 on the upper surface 9ID. The strip 98 is then 13 disposed in the direction Indicated by the arrowed line B
14 and thereb~ glued in place to form the cGnfiguration depicted in E~ig. 13. It ~lill be readily understood that the 16 hot .melt glue 96 ~erves as a means for securing strip 98 to 17 the upper surface 9lD of reinforcing rib 9l, and that when 1~ secured thereto, the strip 98 substantially covers upper 19 surface 9lD of reinforcing rib 9l along its entire lengt!l.
The strip 98 functions as a~ substantially rigid support 21 means for énhan.cing the structural integrity and rlgidity of 22 the reinforcing rib 9l, a furthér description of which will 23 ensue as the detailed description continues. Although not 24 herein speci~ically ` shown, a strip 99 o~~ reinforcing ~ 21814Q7 material, shown in Fig. 15, similar to strip 98, is also 2 secured to the upper surface 90D of reinforcing rib 90 in 3 eY.actly the same way as strip 98 has been herein descr1bed 4 as being secured to reinforcing rib 91, details of which S will not herein again be further described. It will be 6 readily understood by those having ordinary skill, that 7 although strip 98 has been herein described as being 3 constructed of Baltic Bircll plywood, other materials may 9 suitably be used as a su'cstitute e.g. steel, aluminum 10 e~trusions, plastic material, or other suitable material as I l selectively desirQd which is substantially rigid and 12 resilient. Furthermore, reinforcing rib 90 and reinforcing 13 rib 91 may suitably be construc~ed of not only a foam 14 material as herein descrlbed, e.g- BLUE DOW,~M foam, but 15 also a suitable plas~ic material e.g. a selected plastic 16 material, a type of ~ood, or some other suitable material as 17 selectively desired 19 Attention is now directe~ to Fig. lq, which illustrates 20 reinforcing rib 91 ~aving the ,strip 9S attached thereto and 21 further heing laminated to interior ~surface 40B of first 2~ panel member ~1, t~e lamination being desirable to further ~3 secure. the strip ga to relnforcing rib 91, and to further 24 secure reinforcing rib 91 to surface 40B. The lamination of _S
reinforcing rib 9l ~ith the strip 98 secured thereto to interior surface 40B permanently affixes and secures the 3 aforesaid in place upon in~erior surface 40B. As can be 4 seen, the laminaticn involv~s bonding oE llr.pregnating layer 5 lO0 with a: bonding substance lOl e.g. a selected type of 6 resin or ai:dhesive, ~s can be seen as being applied with a 7 trowel 93, and compressing t~e layer lO0 upon Ihe S reinforcing rib 91, the strip ga, and upon portions of the 9 interior surface 40B, to form a laminate layer. Alt~lough 10 any preferred material may l:,e used, layer lO0 is preferably I l comprised of at least two layers = of uni-directional 7 fiberglass cloth that when laminated in place, form two ~3 layers of firmly united material that firmly bond to strip 14 98, reinforcing rib 91, and portions of interior surface 15 qOB. Resins or adhesives suitable for use ~in lamination may 16 comprise a low prGfi le resin, polyurea resln, an epoxy, a 17 polyester resln, o~ other suitable lesin or bonding ~S substance or adhesive~
Fig. 15 illustrates how ,reinforcing rib 9l with the 21 strip 98 secured thereto, and how reinforcing rib 90 with 77 strip 99 secured t~.ereto, appear after lamination has taken 23 place, ~thereby forming reinforcing element 34 and 74 reinforcing element 35, res~ectively, as herein first 7~j . .
disclosed in cor[bination with Fig l. It will be 2 appreciated that the laml~ation of reinforcing rlb 90 with 3 strip 99 secured thereto is laminated using the same 4 technique and method described in combination with Fig. 19, S and will not herein again be specificall / described. The 6 reinforcing eleme~tst 39 and 35, function as reinforcing 7 means for reinforcing panel 30 w11e1l constructed, and for ?3 adding structural integrit ~ to panel 30. The reinforcing 9 means as herein discussed, is the preferred embodiment, and 10 other reinforcing meahs ~ay suitably ~e used in lieu thereof 11 as desired and suitable . It will be readlly appreclated by 12 those skilled in the art, t!lat any number and comblnation of 13 reinforcIng elements may be used in combination with the 14 instant i~vention as desired. --l6 Attention is no~ directed to Fig. lG and 17 which 17 illustrate~ the construction ol~ the second panel me1nber 32.
13 The second panel mel[bér 32 is constructed in much the same 19 way as the first panel memk~er, and so the specific details 70 of construction, ~hich ha~e i~l'ready been herein described in 21 combination with the first panel mer~ber 31, will not herein 27 be again specifically described in enormous detail, as they 2~ will be readily understoQd. As in the construction of the 24 first panel member 31, the construction of the second panel _7 ~ . 21~ 7 member 32 begins wi~h the washing and waxing of portions of mold 55. As c2n be seen in Fig. 16, human h2nd 104 can be 3 seen w2shing upper surf2ce 56A ~,lit~ a spor.ge 105 :prefer2bly with use of co~ventional s02p 2nd w2ter, or other type of non 2br2sive cle2nser (no, herein specifically shown). Once 6 t}le upper surf2ce 56A h2s been sufficiently cle2ned to 7 remove unw~nted dirt or other foreign debris, the upper 8 surf2ce 56A then prefe~rabIy needs [o be w2xed so th2t when 9 the construction of secol~.d p2nel member 32 is complete, it may be easlly r~mo~ed. hlaxing is ~Jell l;.nown, and the Il details of which will not ~.erein be speclfically addressed.
12 However, as can be seen in Fig. 16, a wax_ng substa~ce 106, 13 of any conventioral and prefl~rred type, can be seen 2s being 14 2pplied to: upper surf2ce . 56.~ by me2ns of spre2ding with 2 trowel 107, and b~ eans of spràying w~th a spray device 16 108. It will be readiLy -opreclateQd th2. waxlng substa~ce 17 106 may bè appli~-d to u~er surface 55~. by means of any IS preferred 2nd suitzble metnocl.
Turning specifically to ,Fig. 17, illustr2ted is the 21 construction of seco:~-d p2nel nember 32. Li~.e first panel 22 member 31, secord p2nel member is prefer2bly comprised o~ a 23 plur21ity of super~ osed layers bonded tQsether with a 24 bonding substance e.g. a selected resin or adhesive.
Specific211y, second panel member 32 includes the outermost 2 layer 50 placed upon upper surface 56.i~, the intermediate layer 52 superi~pos~d upon the outer~ost layer, and the 4 lnnermost layer 51 superi~posed upon tlle intermediate layer 52. Each layer, 50, 51, an.d 52, is impregnated with bonding 6 substance 110 as e2ch is cons2cutively superimposed one atop 7 the other. Bonding substc~ce 110 is preferably comprised of S a low profile r~sin, but m,2y also be comprised of a polyurea 9 resin, an epoxy substance, o-r 2 polyester resin, or any other suitable bonding substance or 2dhesive substance 3l Once the bonding substance 110 cures, sets up, or dries, 1~ second panel member ~32 b~comes substantially rigid having l3 exterior s~Irface 12A c~d interior surface 32B, the 14 configuration of which cGn be seen in -~ig. 19. Bo~.ding substanc~ lI0 may ~e= ap~lied by means of any preferred t6 method e.g. spra~ a, coreading, or rolling e.g. with 17 roller lll as illustrated, or any other preferred method as IS d~sired.
Turning now to Fig. 19, i~rus~rated lS tlle next step in 21 the construction of panel 30. ~s can be seen, a bonding 22 substance 115 is seen as having been disposed on portions of 2~ the upper~ surface, 116 and 117, of each respective 24 reinforcing ~ element, 34 2nd 35 . SeGond panel member 32 is 21814~7 then disposed in the direction ind1cated b~ the 2rrowed line 2 C such that the interior sarface 32B becomes engaged with bonding substance 115, thereby engaging the second panel 4 member 32 to the recpective reinforclng elements, 3q and 35 S respectively, to form the configuratiQn of panel 30 6 illustrated in comoination witl~ Fig. 20. As a res~lt of 7 such a configuration, first par.el memL~er 31 and second panel 8 member 32 are - sp2ced ap2rt from one another such that 9 interior s~lrface 32B and interior surface qOB are spaced in ]0 a di2metrically opposed and spaced apart orientation and in I l a generally planar and generally parallel configuration 12 relative ~to Qne another, thereby forming space: 120 13 therebetween within the 2-ea- encompassed by both interlor 14 surfaces, 32B and 40}.
16 With moment2ry reference to Fig. 18, shown is a bucket 17 125 being filled with a first substance 12~, and a second 18 substance 127 Consistent with the preferred embodiment, 19 substance- 12~ being added to bucl~.et 125 includes the low '0 profile resin previously descrihed hereln, and substance 127 21 being added to bucket 125 includes a substance !~nown as Cab-22 o-sil, which is h~ell l~.nown by those having ordinary skill.
23 The low profiIe resin, which may also be another type of ~4 suitable resin or adhesive substance e.g. polyurea resin, an epoxy, or a polyester resin, and the Cab-o-sil are mixed 2 together~ until the mixture ta}.es on the conslstency of 3 peanut butter. This m.ixture ma~:es up the preferred 4 embodiment of bonding substance 115. ~owever, it will be 5 appreciated by those.havirg o-rdinary skill in the art that 6 other substances having cuitable and adequate bondillg or 7 adhesi~e characteristics may be used in lieu of bonding substance 115 as here~ n specifically descrlbed ln 9 combin2tion wlth Fig. 18 and Flg. l9.
1ith ref~erence again ~lirected to Fig. 20, panel 30 is 12 seen disposed intermediate an upper cl2mp fixture 127 and a 13 lower clamp fixture 128 . Lower cla~p ~lx~ure 1, 8 functions 14 as a clamping base agamst which paneL ~30 rests such that I j when upper clamping fixture 127 is disposed in the direction 16 indicated. by the arrowed lir.e D, the panel 30 becomes l7 clamped therein and ~esides intermediate upper clamp fixture 1~ 127 and lowe~ clamp fixture 128.: ~nce panel 30 is clamped 19 in place, insulatinq substance 33 may then be properly disposed within space 120. ~.s can be seen in Fig. 20, a 2I conventional spray gun is shown spraying insulating 22 substance . 33 into space 12Q _ The insuLating substance 33 is 23 pre-ferably comprised of an eYpandable polyurethane foam that ~4 wher sprayed ihto s~ace 17i,~pends t~ sub~tentially iill space 120. Since insulatlng substance ~33 is preferably an 2 expand2ble fo2m substance, p2nel 30 must be clamped down so 3 th2t p2nel 30 coes IlOt bre2k 2p2rt 2s 2 result of the 4 lntern21 pressure exerted by the i~02m as it expands within S sp2ce 120. Any preferreci me2ns Qf cl2mplng, e-g- th2t 6 herein specific211y descr~bed in rel2tion to the preferred 7 embodi.ment, .m2y be used f~r securing or= cl2mping panel 30.
S Although insul2ting subst2!lce 33: h2s been hereln described 9 2s being a pQlyureth2ne fGam, other subst2nces suit2ble for ]0 use with the inst2nt i~vention m2y 21so be used 2s I l selectively desired, 2nd t:~2t the polyureth2ne fo2m has been 12 herein disclose~ merely for th2 purpose . of illustr2tion of l3 the preferred e~rboc!iment. Cnce insul2ting subst2nce 33 14 exp2nds 2nd cures or dr:es, the panel ~0 is complete, lS thereby fo.rming l~.e e~!bodi-ent first illustrated in Fiq. 1.
l7 Turning no~ to Fig. 21:,- sho~Jn 2re two panels, a iS subst2nti211y plæl2r first p2nel 135 h2vinq 2 le2ding edge 19 135A, and 2 substanti211y planar second panel 136 h2ving a le2ding edge 136.~. FQr the purpose of =orient2tion, first 21 panel 135 :znd second panel 136 2re prefer2bly constructed 2' simil2r to: first panel member 31. The purpose of Fig. 21 is 23 to illustrate how portions of first panel 135 and portiQns 4 of panel 136, proxim2te leading edge 135 and leading edge 136 respèctively, may be manuf2ctured to include: a first 2 recessed portion 135B and second recessed portion 136B, 3 respectively As a result of such a configuration, leading 4 edge 135A and leading edge 136A may be brought in S juxtaposition in a diametrlcally opposed configuration and 6 then laminated together, thereby securing first panel 135 to 7 second panel 136 LO create z larger panel section, being g generally designated by the reference chzracter 137.
~lith continuing reference tQ Fig. ~1, and additional Il reference~ to Fig. 2~,: to properly secure first panel 135 to secQnd panel L36, not onIy should first p2nel 135 and second 1~panel 136: be 12mir~ted together by aGpiying a laminate layer ~4proximate first recessed portion 135B 2rd second recessed 15portion 135B, but also pro~iimate the bottGm surfaces (not ]6herein specificall~ s'~Gl~n) of~ the first pan~l 135 and tlle 17second panel 136 directl~y op~osite th~ r~spective first 18 recessed portion 1353 and the second recessed portion 136B.
1~ Like the preferLed laminatiol1 method hereln described in 20combination with Fig. lq, the laminat_on herein involues 2Idisposing a first layer lqO s~ch t~a~ first layer lqO
22overlaps and substantially covers each of the respective 2~ recessed portions, 135B and 135B respectively, superimposing 24 a second layer 141 upon first layer lqO, and impregnating , ~
~ 2181407 the first ~and secQnd layers, 140 and lql, witll bonding 2 substance 142 to bond the layers lq~ and 191 together and to 3 bond the first and second pane-ls, 135 and 136 respectively, 4 together. Although any preferred material may be used, S first layer LqO and ~seco~d layer 191 are preferably 6 comprised of a uni-directLonal flberglass cloth. Al[hough 7 the lamination herein described dlscloses two layers, any 8 number of~ layers may be used in the lamination as suitably 9 desired. The bonding subs;ance 142 suitable for use in the above described lamin2tion may include a low profile resin, I l polyurea resin, 2n epoXy, a polyester~ resin, or othe~
1~ suitable resin, bonding substance, or adhesive.
14 With continuing reference to Fig. 22, once first panel IS 135 and second pcnel 136 ha~e been lzminated together, it is 16 desirable tQ ap~ly a layer of cementing substance 145 on top 17 of the 12mination la~ier disposed Jithi~ lle first recessed 18 portion 135B and the seco~d recessed portion 136B. The Ig cementing substance~ 145 ~ay be applied by use of any preferred. method. IIowever, a' satisfactory way of applying 21 cementing substa~ce 145 is through the use of a trowel 146 22 which can be seen as beillg held by human hand lq7 for ~3 spreading the cement~ng substance lq5 atop the layer of 24 laminate shown. ~lthough any preferred cementing substance 21814~7 lq5 may be used in combiration with the instant invention, 2 it must be resilient and strong when it cures or dries, and 3 may therefore consist of a resilient caulking substance, or 4 a substance referred to as i30ndo,~ a comm.on substànce readily known to those having ordinary skill and typicalLy used for 6 repairin~ external au::omooile parts that have been damaged 7 or compromised_ Once the cementing substance 145 has cured or dried sufficien~ly, it may then be sanded smooth such as 9 with a sanding element 148 ~eld by human hand 149, as can be seen with reference: to Fig. 23. It will be readily I l appreciated in light of t~e foregoing discussion, that two 17 or more panels, such as preferred panel 30 seen in Fig. 1, 13 may be joined together using the method of joining flrst 14 panel 135 and second panel 136 herein discussed in combination with Fig. 21, F:ig. 22, and Fig. 23. However, it 16 will further be ap~7reGiated that in order to join a l7 plurality of panels toge~her, the various panel members must l8 be first: joined together prior to introducing insulating 19 substance 33 theretQ to for~ a completed panel segment, such as panel segment 150 illustrated in Fig. 23, which shows 21 panel ~51 joined to panel ~ 152. It will be readily 22 appreciated by those havin.g ordinary skill that although the 23 above discussion discloses wllat is believed to the preferred 24 method of joining a plurality of panels together, any ` 2181407 preferl~ed and suitcble rnethod ~f joining m2y be used as 2 selectlvely desired.
,6
Claims (19)
1. A panel for use in constructing a structure, said panel comprising:
a first panel member having an interior surface and an exterior surface;
a second panel member having an interior surface and an exterior surface, said interior surface of said second panel member being spaced from and generally parallel to said interior surface of said first panel member thereby creating a space intermediate said first panel member and said second panel member;
an insulating substance substantially filling said space; and reinforcing means intermediate said first panel member and said second panel member proximate said space for adding structural integrity and strength to said panel.
a first panel member having an interior surface and an exterior surface;
a second panel member having an interior surface and an exterior surface, said interior surface of said second panel member being spaced from and generally parallel to said interior surface of said first panel member thereby creating a space intermediate said first panel member and said second panel member;
an insulating substance substantially filling said space; and reinforcing means intermediate said first panel member and said second panel member proximate said space for adding structural integrity and strength to said panel.
2. The panel of claim 1, wherein said first panel member includes a plurality of firmly united superimposed layers of material, said first panel member being substantially rigid and generally planar.
3. The panel of claim 1, wherein said second panel member includes a plurality of firmly united superimposed layers of material, said second panel member being substantially rigid and generally planar.
4. The panel of claim 1, wherein said reinforcing means includes:
a first reinforcing element; and a second reinforcing element, said first reinforcing element and said second reinforcing element residing therein said insulating substance proximate said space
a first reinforcing element; and a second reinforcing element, said first reinforcing element and said second reinforcing element residing therein said insulating substance proximate said space
5. The panel according to claim 4, wherein said first reinforcing element includes:
a first elongate reinforcing rib coupled to portions of said interior surface of said first panel member; and a strip of reinforcing material secured to portions of said first elongate reinforcing rib.
a first elongate reinforcing rib coupled to portions of said interior surface of said first panel member; and a strip of reinforcing material secured to portions of said first elongate reinforcing rib.
6. The panel of claim 5, wherein said first reinforcing element further includes a laminate layer adhesively coupled to portions of said strip of reinforcing material and said first elongate reinforcing rib, and to said interior surface of said first panel members.
7. The panel of claim 6, wherein said reinforcing element further includes an upper surface, said upper surface being coupled to portions of said interior surface of said second panel member.
8. The panel according to claim 4, wherein said second reinforcing element includes:
a second elongate reinforcing rib coupled to portions of said interior surface of said first panel member;
and a strip of reinforcing material secured to portions of said second elongate reinforcing rib.
a second elongate reinforcing rib coupled to portions of said interior surface of said first panel member;
and a strip of reinforcing material secured to portions of said second elongate reinforcing rib.
9. The panel of claim 8, wherein said second reinforcing element further includes a laminate layer adhesively coupled to portions of said strip of reinforcing material and said second elongate reinforcing rib, and to said interior surface of said first panel member.
10. The panel of claim 9, wherein said reinforcing element further includes an upper surface, said upper surface being coupled to portions of said interior surface of said second panel member.
11. A method of manufacturing a panel for use in constructing a structure, said method comprising the steps of providing a substantially rigid generally planar first panel member having an interior surface and an exterior surface;
providing a substantially rigid generally planar second panel member having an interior surface and an exterior surface;
spacing apart said first panel member from said second panel member such that said interior surface of said first panel member is spaced from and generally parallel to said interior surface of said second panel member thereby creating a space intermediate said first panel member and said second panel member;
providing reinforcing means proximate said space for adding structural integrity and strength to said panel;
and substantially filling said space with an insulating substance.
providing a substantially rigid generally planar second panel member having an interior surface and an exterior surface;
spacing apart said first panel member from said second panel member such that said interior surface of said first panel member is spaced from and generally parallel to said interior surface of said second panel member thereby creating a space intermediate said first panel member and said second panel member;
providing reinforcing means proximate said space for adding structural integrity and strength to said panel;
and substantially filling said space with an insulating substance.
12. The method of claim 11, wherein said step of providing a first panel member includes the step of firmly uniting a plurality of superimposed layers of material with a bonding substance to form said first panel member.
13. The method of claim 11, wherein said step of providing said second panel member includes the step of firmly uniting a plurality of superimposed layers of material with a bonding substance to form said second panel member.
14. The method of claim 11, wherein said step of providing reinforcing means includes the step of providing 2 plurality of reinforcing elements.
15. The method of claim 14, wherein said step of providing a plurality of reinforcing elements further includes the steps of:
providing a first reinforcing element; and providing a second reinforcing element, spaced apart from said first reinforcing element:
providing a first reinforcing element; and providing a second reinforcing element, spaced apart from said first reinforcing element:
16. The method of claim 15, wherein said step of providing a first reinforcing element further includes the steps of:
providing a first elongate reinforcing rib;
securing said first elongate reinforcing rib to portions of said interior surface of said first panel member;
securing a strip of reinforcing material to portions of said first elongate reinforcing rib;
laminating said first elongate reinforcing rib having said strip of reinforcing material secured thereto to portions of said interior surface of said first panel member to complete the construction of said first reinforcing element; and securing portions of said first reinforcing element to portions of said interior surface of said second panel member.
providing a first elongate reinforcing rib;
securing said first elongate reinforcing rib to portions of said interior surface of said first panel member;
securing a strip of reinforcing material to portions of said first elongate reinforcing rib;
laminating said first elongate reinforcing rib having said strip of reinforcing material secured thereto to portions of said interior surface of said first panel member to complete the construction of said first reinforcing element; and securing portions of said first reinforcing element to portions of said interior surface of said second panel member.
17. The method of claim 15, wherein said step of providing a second reinforcing element further includes the steps of:
providing a second elongate reinforcing rib;
securing said second elongate reinforcing rib to portions of said interior surface of said first panel member;
securing a strip of reinforcing material to portions of said second elongate reinforcing rib;
laminating said second elongate reinforcing rib having said strip of reinforcing material secured thereto to portions of said interior surface of said first panel member to complete the construction of said second reinforcing element; and securing portions of said second reinforcing element to portions of said interior surface of said second panel member.
providing a second elongate reinforcing rib;
securing said second elongate reinforcing rib to portions of said interior surface of said first panel member;
securing a strip of reinforcing material to portions of said second elongate reinforcing rib;
laminating said second elongate reinforcing rib having said strip of reinforcing material secured thereto to portions of said interior surface of said first panel member to complete the construction of said second reinforcing element; and securing portions of said second reinforcing element to portions of said interior surface of said second panel member.
18. A method of joining a substantially planar first panel to a substantially planar second panel, said method comprising the steps of:
forming a first recessed portion proximate said first panel;
forming a second recessed portion proximate said second panel;
juxtaposing said recessed portion proximate said second recessed portion;
bonding said first panel and said second panel together proximate said first recessed portion and said second recessed portion thereby producing a substantially planar panel section.
forming a first recessed portion proximate said first panel;
forming a second recessed portion proximate said second panel;
juxtaposing said recessed portion proximate said second recessed portion;
bonding said first panel and said second panel together proximate said first recessed portion and said second recessed portion thereby producing a substantially planar panel section.
19. The method of claim 18, wherein said step of bonding said first panel and said second panel includes the step of laminating said first panel to said second panel proximate said first recessed portion and said second recessed portion.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US60862796A | 1996-03-01 | 1996-03-01 | |
| US08/608,627 | 1996-03-01 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2181407A1 true CA2181407A1 (en) | 1997-09-02 |
Family
ID=24437323
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2181407 Abandoned CA2181407A1 (en) | 1996-03-01 | 1996-07-17 | Panel and method of making panel |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2181407A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112828533A (en) * | 2021-01-22 | 2021-05-25 | 中际(重庆)车辆轻量化科技有限公司 | Processing method of section bar |
-
1996
- 1996-07-17 CA CA 2181407 patent/CA2181407A1/en not_active Abandoned
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112828533A (en) * | 2021-01-22 | 2021-05-25 | 中际(重庆)车辆轻量化科技有限公司 | Processing method of section bar |
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| Date | Code | Title | Description |
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| FZDE | Dead |