US20080148663A1 - Interior structural panel - Google Patents

Interior structural panel Download PDF

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Publication number
US20080148663A1
US20080148663A1 US11541527 US54152706A US2008148663A1 US 20080148663 A1 US20080148663 A1 US 20080148663A1 US 11541527 US11541527 US 11541527 US 54152706 A US54152706 A US 54152706A US 2008148663 A1 US2008148663 A1 US 2008148663A1
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US
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Application
Patent type
Prior art keywords
foam
core
panel
face
invention
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
Application number
US11541527
Inventor
J. Edward Peede
Thomas P. Phillips
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
INTERIOR PRODUCTS Inc
Original Assignee
INTERIOR PRODUCTS Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/296Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material

Abstract

A structural panel for interior use made of a polystyrene foam core of either extruded polystyrene foam (XPF) or an expanded polystyrene foam (EPF) and a rigid face material having a higher density and being thinner than said foam core and attached to each opposed face of said foam core to capture said foam core.

Description

    BACKGROUND OF THE INVENTION
  • [0001]
    1. Field of the Invention
  • [0002]
    The invention relates to an economical light weight structural panel comprising an extruded or expanded polystyrene foam core and thin face materials such as hardboard, fiberboard and various kinds of plywood designed for use as an interior panel such as wall partitions, ceiling panels, store fixtures, exhibits, furniture, signage, shelving theater props, table tops, motor homes, boats, etc. and is used as a replacement for particle board, plywood, medium fiber density board and other panels designed for interior use.
  • [0003]
    2. Related Art
  • [0004]
    Composite structural panels of the general type of the invention are of course known to the art. Such panels may consist of an insulating core such as plastic foam and a pair of opposed outer facings bonded to the panel's insulating core. However, the structural panel of the invention is a more economical and light weight structural panel designed for use as an interior panel than known structural panels.
  • [0005]
    U.S. Pat. No. 2,124,921; LEDERER; Composite Building Material; discloses various combinations of materials forming a slab covered on one side with wood veneer and a body consisting of a mixture of wood wool and cement.
  • [0006]
    U.S. Pat. No. 4,564,554; MIKUSKI; Composite Sheathing; discloses a laminated composite sheathing including a thermally insulating layer of foam bonded on one or both faces to a relatively rigid laminated sheet preferably formed of a fiberboard core adhesively secured between facing sheets of kraft paper bonded together with a resilient polymeric material.
  • [0007]
    U.S. Pat. No. 6,534,174; Ouellette et al; Surface Bonded Entangled Fibrous Web and Method of Making and Using; discloses an absorbent low-linting structure comprising an entangled web of synthetic fibers, wherein fibers of at lest one of the top surface and the bottom surface are surface bonded by thermal or adhesive bonding.
  • [0008]
    U.S. Pat. No. 6,599,621; Porter; High Strength Structural Insulated Panel; discloses a structural building panel including an inner insulating core of plastic foam and a pair of opposed outer facings bonded to the panel's insulating core.
  • [0009]
    U.S. Pat. No. 6,869,669; Jensen et al; Fiber-Reinforced Sandwich Panel; discloses a sandwich panel having first and second face panels formed of a fiber-reinforced cementitious material. A support frame supports the first and second face panels in a spaced apart configuration.
  • BRIEF DESCRIPTION OF THE INVENTION
  • [0010]
    The foam core board product of the invention with rigid face materials on opposing sides result in such a product that is 80% lighter than plywood, particle board and MDF. The face materials enable conventional attachment methods and edge treatments. The foam board product of the invention may be used for a variety of applications including shelving, wall systems, ceiling panels, displays, exhibits, doors, cabinets, table tops, or any application where weight is a consideration.
  • [0011]
    The foam core product of the invention is constructed by capturing a polystyrene foam core with higher density face panels to provide a strong light weight panel with structural integrity. Two core materials are used in this product One is an extruded polystyrene foam (XPF) that is closed cell in structure and provides a consistent and uniform surface to machine. The other core material is an expanded polystyrene foam (EPF) with a slightly lower density. The sandwich panel construction method of the invention incorporates the use of thinner outer panels bonded to a thicker lighter core which provides for a strong light panel that can be compared to a truss beam. The panel concept spacing thin stronger face panels apart with a thicker core ensures that the combination will be stiff and strong.
  • [0012]
    The foam core product of the invention is moisture resistant to water. The face panels are laminated with moisture resistant glue leaving only the face susceptible to moisture.
  • [0013]
    A variety of edging options include edge capture, edge insert, outer edge band, edge banding and corner post.
  • [0014]
    The panels of the invention enable hinges to be installed and different corner options.
  • BRIEF DESCRIPTION OF THE DRAWING
  • [0015]
    The above objects, features and advantages of the invention are readily apparent from a consideration of the following description of the best mode of carrying out the invention when taken in conjunction with the following drawing representing a preferred embodiment of carrying out the invention;
  • [0016]
    The sole FIGURE is a perspective view of the balanced constructed foam board of the invention showing the thin rigid facing panels attached to opposed sides of the polystyrene foam core.
  • DETAILED DESCRIPTION
  • [0017]
    As shown in the sole FIGURE, the balanced constructed foam board 10 is made by capturing a polystyrene foam core 14 with high density, relatively thin, face panels 12 and 16 which are attached to the foam core 14 by a moisture resistant glue 18 and 20. Preferably two core materials are used in the foam board 10, namely an extruded foam (XPF) that is closed cell in structure and provides a consistent and uniform surface to machine; and an expanded polystyrene foam (EPF) with a slightly lower density.
  • [0018]
    The sandwich construction just described incorporates the use of thinner outer panels 12 and 16 bonded to a thicker light foam core 14 thereby providing a strong, light panel that can be compared to a truss beam.
  • [0019]
    The core thickness and thickness of the face materials may be varied to suit the thickness of the balanced constructed foam board.
  • [0020]
    Examples of face materials are hardboard, fiberboard, Lauan plywood, poplar plywood and birch plywood.
  • [0021]
    Therefore it is desired that the present invention not be limited to the embodiments specifically described, but that it include any and all such modifications and variations that would be obvious to those skilled in the panel construction art. It is my intention that the scope of the present invention should be determined by any and all such equivalents of the various terms and structure as recited in the following annexed claims.

Claims (7)

  1. 1. A structural panel for interior use, comprising:
    a polystyrene foam core; and
    a rigid face material having a higher density and being thinner than said foam core and attached to each opposed face of said foam core to capture said foam core.
  2. 2. A structural panel as in claim 1, wherein said foam core is an extruded polystyrene foam (XPF).
  3. 3. A structural panel as in claim 1, wherein said foam core is an expanded polystyrene foam (EPF).
  4. 4. A structural panel as in claim 2, wherein said rigid face material is from the group comprising hardboard, fiberboard and various kinds of plywood.
  5. 5. A structural panel as in claim 3, wherein said rigid face material is from the group comprising hardboard, fiberboard and various kinds of plywood.
  6. 6. A structural panel as in claim 4, wherein the rigid face material is laminated with moisture resistant glue to said foam core.
  7. 7. A structural panel as in claim 5, wherein the rigid face material is laminated with moisture resistant glue to said foam core.
US11541527 2006-10-03 2006-10-03 Interior structural panel Abandoned US20080148663A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US11541527 US20080148663A1 (en) 2006-10-03 2006-10-03 Interior structural panel

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US11541527 US20080148663A1 (en) 2006-10-03 2006-10-03 Interior structural panel

Publications (1)

Publication Number Publication Date
US20080148663A1 true true US20080148663A1 (en) 2008-06-26

Family

ID=39540900

Family Applications (1)

Application Number Title Priority Date Filing Date
US11541527 Abandoned US20080148663A1 (en) 2006-10-03 2006-10-03 Interior structural panel

Country Status (1)

Country Link
US (1) US20080148663A1 (en)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100088981A1 (en) * 2008-10-09 2010-04-15 Thermapan Structural Insulated Panels Inc. Structural Insulated Panel for a Foundation Wall and Foundation Wall Incorporating Same
US20100101182A1 (en) * 2008-10-23 2010-04-29 John Murchie Composite panel
US20140331584A1 (en) * 2013-05-13 2014-11-13 Victor Amend Dividing wall panel and method of manufacturing same
US9010053B1 (en) * 2014-01-28 2015-04-21 Robert Jeffrey Kupferberg High strength thermal barrier panel for an H.V.A.C. unit housing
US9089229B2 (en) 2012-07-26 2015-07-28 Hewlett-Packard Development Company, L.P. Frame kits and frames
US9309671B2 (en) 2012-03-01 2016-04-12 Owens Corning Intellectual Capital, Llc Structural panel and method for making same
US9624666B2 (en) 2012-05-18 2017-04-18 Nexgen Framing Solutions LLC Structural insulated panel framing system

Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5081810A (en) * 1990-06-11 1992-01-21 Emmert Second Limited Partnership Building panel
US5407589A (en) * 1991-07-05 1995-04-18 Lever Brothers Company, Division Of Conopco, Inc. Fabric softening composition
US5638651A (en) * 1994-08-25 1997-06-17 Ford; Vern M. Interlocking panel building system
US5735092A (en) * 1996-09-23 1998-04-07 Bridgestone/Firestone, Inc. Composite roofing members having improved dimensional stability and related methods
US5834082A (en) * 1992-05-04 1998-11-10 Webcore Technologies, Inc. Reinforced foam cores and method and apparatus of production
US6044603A (en) * 1994-10-07 2000-04-04 Bader; Harold Load-bearing lightweight insulating panel building component
US6205729B1 (en) * 1998-11-18 2001-03-27 William H. Porter Asymmetric structural insulated panel
US6358599B1 (en) * 1999-04-30 2002-03-19 The Dow Chemical Company Alkenyl aromatic polymer foam laminates
US20030041544A1 (en) * 2001-03-27 2003-03-06 Rusek Stanley J. Structural insulated sheathing and related sheathing methods
US6564521B1 (en) * 2000-05-12 2003-05-20 Brown Paul A Structural sandwich panels and method of manufacture of structural sandwich panels
US6599621B2 (en) * 2001-03-20 2003-07-29 William H. Porter High strength structural insulated panel
US6854228B2 (en) * 2000-04-14 2005-02-15 602225 N. B. Inc. Prefabricated sealed composite insulating panel and method of utilizing same to insulate a building
US6872673B2 (en) * 2002-07-18 2005-03-29 Edward Sider & Company Laminate and use of such laminate as a facer in making insulation boards and other products

Patent Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5081810A (en) * 1990-06-11 1992-01-21 Emmert Second Limited Partnership Building panel
US5407589A (en) * 1991-07-05 1995-04-18 Lever Brothers Company, Division Of Conopco, Inc. Fabric softening composition
US5834082A (en) * 1992-05-04 1998-11-10 Webcore Technologies, Inc. Reinforced foam cores and method and apparatus of production
US5638651A (en) * 1994-08-25 1997-06-17 Ford; Vern M. Interlocking panel building system
US6044603A (en) * 1994-10-07 2000-04-04 Bader; Harold Load-bearing lightweight insulating panel building component
US5735092A (en) * 1996-09-23 1998-04-07 Bridgestone/Firestone, Inc. Composite roofing members having improved dimensional stability and related methods
US6205729B1 (en) * 1998-11-18 2001-03-27 William H. Porter Asymmetric structural insulated panel
US6358599B1 (en) * 1999-04-30 2002-03-19 The Dow Chemical Company Alkenyl aromatic polymer foam laminates
US6854228B2 (en) * 2000-04-14 2005-02-15 602225 N. B. Inc. Prefabricated sealed composite insulating panel and method of utilizing same to insulate a building
US6564521B1 (en) * 2000-05-12 2003-05-20 Brown Paul A Structural sandwich panels and method of manufacture of structural sandwich panels
US6599621B2 (en) * 2001-03-20 2003-07-29 William H. Porter High strength structural insulated panel
US20030041544A1 (en) * 2001-03-27 2003-03-06 Rusek Stanley J. Structural insulated sheathing and related sheathing methods
US6872673B2 (en) * 2002-07-18 2005-03-29 Edward Sider & Company Laminate and use of such laminate as a facer in making insulation boards and other products

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100088981A1 (en) * 2008-10-09 2010-04-15 Thermapan Structural Insulated Panels Inc. Structural Insulated Panel for a Foundation Wall and Foundation Wall Incorporating Same
US20100101182A1 (en) * 2008-10-23 2010-04-29 John Murchie Composite panel
US8438816B2 (en) * 2008-10-23 2013-05-14 John Murchie Composite panel
US8875474B2 (en) 2008-10-23 2014-11-04 John Murchie Composite panel
US9309671B2 (en) 2012-03-01 2016-04-12 Owens Corning Intellectual Capital, Llc Structural panel and method for making same
US9624666B2 (en) 2012-05-18 2017-04-18 Nexgen Framing Solutions LLC Structural insulated panel framing system
US9089229B2 (en) 2012-07-26 2015-07-28 Hewlett-Packard Development Company, L.P. Frame kits and frames
US20140331584A1 (en) * 2013-05-13 2014-11-13 Victor Amend Dividing wall panel and method of manufacturing same
US9010053B1 (en) * 2014-01-28 2015-04-21 Robert Jeffrey Kupferberg High strength thermal barrier panel for an H.V.A.C. unit housing
EP3043991A1 (en) * 2014-01-28 2016-07-20 Kupferberg, Robert Jeffrey High strength thermal barrier panel for an h.v.a.c. unit housing
EP3043991A4 (en) * 2014-01-28 2017-05-03 Kupferberg Robert Jeffrey High strength thermal barrier panel for an h.v.a.c. unit housing

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Legal Events

Date Code Title Description
AS Assignment

Owner name: INTERIOR PRODUCTS, INC., GEORGIA

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:PEEDE, ED;PHILLIPS, THOMAS P;REEL/FRAME:019366/0031

Effective date: 20060922