US3616590A - Prefabricated core structure for a prefabricated structural panel - Google Patents

Prefabricated core structure for a prefabricated structural panel Download PDF

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US3616590A
US3616590A US864605A US3616590DA US3616590A US 3616590 A US3616590 A US 3616590A US 864605 A US864605 A US 864605A US 3616590D A US3616590D A US 3616590DA US 3616590 A US3616590 A US 3616590A
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members
prefabricated
core structure
panel
row
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Albert Shotmeyer
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
    • E04C2/365—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels by honeycomb structures
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24149—Honeycomb-like
    • Y10T428/24157—Filled honeycomb cells [e.g., solid substance in cavities, etc.]

Definitions

  • This invention relates tostructural members, and more particularly to a novel prefabricated core structure for a prefabricated structural panel having improved heat and sound insulation properties, and especially adapted for use as an interior or an exterior building wall.
  • the invention comprises a novel prefabricated core structure for a prefabricated structural panel having filler material to form opposite parallel walls.
  • the filler material may be selected from the conventional cementitious filler materials such as Portland cement, stucco, sand, gypsum plaster and the like, and may use large proportions of vermiculite or similar material if lightness in weight is a factor.
  • the core is made in the form of a honeycomb unit of a light material, such as polystyrene, marketed under various names such as Styrofoam, for example, and comprises a plurality of relatively short lengths of polystyrene in side-by-side relationship to form rows, and a series of rows arranged in tiers, the longitudinal axes of the short lengths of polystyrene in one row being laterally offset 3,516,59 Patented Nov. 2, 1971 relative to the longitudinal axes of the lengths in an adjoining row to produce the individual cells of the honeycomb unit.
  • the rows and tiers are interconnected by a series of elongated tubing of plastic material or coated hard cardboard material.
  • the tubing is disposed in vertical and horizontal rows passing through the individual lengths of the honeycomb unit to maintain them in assembled relation, and the individual tubes, comprising the tubing, are extended on each end beyond the honeycomb unit to the end of the panel when the core is embedded within a panel.
  • the tubes are arranged in symmetrical form so that, when the panels are assembled in a wall and the like by conventional tongue and groove joints, the tubes in one panel axially align with those in an adjoining panel to form a continuous conduit through which Water pipes, electrical cable, and the like may be extended.
  • FIG. 1 is an end view of a preferred form of my novel prefabricated core structure, illustrating the arrangement of parts forming the honeycomb unit and its position in a finished panel shown in broken lines;
  • FIG. 2 is a top plan view of the construction of FIG. 1, illustrating, by the use of broken lines, a phantom prefabricated structural panel embodying the core structure.
  • the core structure 10 includes a honeycomb or cellular unit 14 made up of a plurality of elongated members 16 and half members 18.
  • the members 16 and 18 can be made of any desired form in section, such :as circular, oval, elliptical, triangular, square, rectangular or other angular form, and are disposed in rows and in tiers to form a plurality of elongated cells 20 between them.
  • the members 16 are hexagonal in cross section, as seen in FIG. 1, and are disposed in the rows I, II, III, IV and V.
  • Each row includes a plurality of the members 16, arranged side-by-side in abutting relation, the angles or corners engaging in line contact.
  • the individual rows 1, II, III, IV and V are stacked in tiers as shown, with the upper angles or corners of one row or tier in line contact with the lower angles or corners of an adjacent row or tier.
  • the longitudinal axes of the members 16 in one row or tier are laterally offset relative to the longitudinal axes of the members 16 in an adjoining row or tier.
  • the members 16 and 18 can be made of any desired material, such as wood, metal, cardboard, plastic, etc., but it is preferred that they be solid and made of a plastic material, preferably polystyrene marketed under various names, such as Styrofoam, for example. This latter material is particularly adapted for a core structure in a panel, because it is light, has the desired strength for its purpose, is not affected by moisture or water, and has exceptionally low heat and sound conduction characteristics.
  • the members 16 and 18 are held in assembled relation by a plurality of tie rods forming a tubing system including a pair of vertically disposed tubular members 22 and 23, and first group comprising four horizontally disposed tubular members 24, 26, 28 and 30.
  • the vertical tubular member 22 passes transversely through the mid portion of each of the left hand members 16 in the rows I, III and V, and through the right hand angles or corners of the half members 18 and through the left hand angles or corners of the adjacent members 18 in the rows II and IV.
  • the other vertical tubular member 23 passes transversely through the center of the right hand end members 16 of the rows I, III and V, and through the left hand angles or corners of the right hand half members 18 and through the right hand angles or corners of the adjacent members 16 in rows II and IV.
  • the horizontally extending tubular members 24, 26, 28 and 30 are disposed in pairs on opposite sides of the vertically extending tubular members 22 and 23, the tubular members 24 and 28 being in parallel relation and on one side of a plane passing through the longitudinal axes of the vertically extending tubular members 22 and 23, and the tubular members 26 and 30 being in parallel relation and on the other side of said plane.
  • the three planes lying in the longitudinal axes of the tubular members 22 and 23, the tubular members 24 and 28, and the tubular members 26 and 30, therefore, are arranged in parallel, spaced, relation.
  • the horizontally extending tubular member 24 extends transversely through one end of the elongated members 16 of row I; the tubular member 26 extends transversely through the opposite ends of the elongated members 16 and half members 18 of row II; the tubular member 28 extends transversely through one end of the elongated members 16 and half members 18 of row IV, directly below the tubular member 24 in row I and through the same ends of the members 16; and the tubular member 30 extends transversely through the opposite ends of the elongated members 16 of row V, directly below the tubular member 26 in row II and through the same ends of the members 16.
  • the tubular members 22, 23, 24, 26, 28 and 30 are shown in the drawings as extending beyond the honeycomb unit 14 to the ends of the structural panel 12, the latter being provided with tongues 32 and grooves 34 to facilitate assembly of a wall or other structural part.
  • two adjoining edges have tongues while the other two adjoining edges have grooves.
  • This arrangement of tongues and grooves provides a symmetrical structure wherein, in assembly, the longitudinal axes of the tubular members in one panel align with the longitudinal axes of the tubular members in an adjoining panel.
  • the vertical tubular members 22 and 23 extend into the tongue 32, as seen in the upper part of FIG. 1, and terminate at the bottom of the groove 34 as seen in the lower part of the figure.
  • the horizontal tubular members 24, 26, 28 and 30 terminate at the ends of the panel proper.
  • the prefabricated core structure can be incorporated into a structural panel 12 as follows:
  • a form of the desired size and shape can be used. Assuming a 4-inch thick panel, wherein the elongated members 16 and 18 are three inches long, one pours on the bottom of the form a layer one half inch thick of gravel or any filler material used, which is spread evenly.
  • the prefabricated core structure 10 is deposited on this one-half inch thick layer so that the tubular members contact the sides of the form. Material may be inserted into the ends of the tubular members to keep out the filler material or any other foreign matter.
  • the tubular members may be made longer than required in the finished panel, so that, when inserted in the form, the ends thereof extend outside the form in suitable holes provided in the sides of the form.
  • Filler material is poured over the core structure 10 in the form, so that the material passes into and through the cells 20, until a 4-inch depth is attained, forming a solid layer one-half thick above the core. After the filler material has set, the finished panel is removed from the form, and the superfluous ends of the tubular members which extend beyond the panel are cut off.
  • the prefabricated core structure shown in the drawing is intended for a small finished panel, and therefore a relatively few elongated members 16 and 18 are used. It is evident that considerably more of such members, as well as more tubular members, are required for larger panels, assembled in the same manner.
  • the ends of the tubular members in one panel align with the ends of the ends of the tubular members in an adjoining panel, in axial alignment, thereby providing a structure through which pipes and electrical conduits and the like can readily be inserted.
  • a prefabricated core structure for a prefabricated structural panel comprising: a plurality of elongated members disposed in side-by-side relation to form a plurality of rows, each of said members being hexagonal in cross section to provide a plurality of corners, the elongated members in one row being disposed in abutting relation with the elongated members of adjacent rows to form a tiered unit, the longitudinal axes of the members in one row being laterally offset relative to the longitudinal axes of the members in an adjacent row, whereby the members in one row are in corner-to-corner contact with the members in an adjacent row, forming a honeycomb unit having a plurality of elongated separated cells of triangular cross section; and a plurality of tie rods passing through and interconnectin g said members into a single unit.
  • tie rods comprise tubular members extending beyond said honeycomb unit to points corresponding to the ends of a structural panel when incorporated in a structural panel.
  • a prefabricated core structure for a prefabricated structural panel comprising: a plurality of elongated members disposed in side-by-side relation to form a plurality of rows, each of said members being polygonal in cross section to provide a plurality of corners, the elongated members in one row being disposed in abutting relation with the elongated members of adjacent rows to form a tiered unit, the longitudinal axes of the members in one row being laterally offset relative to the longitudinal axes of the members in an adjacent row to provide a plurality of elongated cells; and a plurality of tie rods passing through and interconnecting said members into a single unit, sai dtie rods including a first group and a second group of tubular members, the members in one group being disposed substantially at right angles to the members of the other group, the tubular members in the first group passing through and interconnecting the ends of the elongated members, and the tubular members in the second group passing through and interconnecting the mid portions of

Abstract

A PREFABRICATED CORE STRUCTURE FOR A PREFABRICATED STRUCTURAL PANEL MADE UP OF A PLURALITY OF RELATIVELY SHORT, SOLID, MEMBERS ARRANGED IN SIDE-BY-SIDE ABUTTING RELATION IN TIERED ROWS HAVING SPACES BETWEEN THE MEMBERS TO FORM A HONECOMB STRUCTURE, AND A SERIES OF ELONGATED TUBULAR MEMBERS DISPOSED AT RIGHT ANGLES TO EACH OTHER AND PASSING THROUGH THE HONECOMB STRUCTURE TO RETAIN THE MEMBERS IN ASSEMBLED RELATION.

Description

Nov. 2, 1971 A. SHOTMEYER 3,615,590
PREFABRICATED. CORE STRUCTURE FOR A PREFABRICATED STRUCTURAL PANEL Filed Oct. 8, 1969 Pm m m V n m ALIBERT SHOTMEYER ATTORNEY United States Patent 3,616,590 PREFABRICATED CORE STRUCTURE FOR A PREFABRICATED STRUCTURAL PANEL Albert Shotmeyer, Wyckotf, NJ.
(46 Westerly Road, Saddle River, NJ. 07458) Filed Oct. 8, 1969, Ser. No. 864,605 Int. Cl. E04c 2/10, 2/36 US. Cl. 52-663 3 Claims ABSTRACT OF THE DISCLOSURE BACKGROUND OF THE INVENTION Field of the invention This invention relates tostructural members, and more particularly to a novel prefabricated core structure for a prefabricated structural panel having improved heat and sound insulation properties, and especially adapted for use as an interior or an exterior building wall.
Because of the rapidly increasing costs of building construction, resulting both from the increased costs of building materials and labor, both skilled and unskilled, there has been a rapid acceleration in efforts to devise ways and means to reduce such costs, mostly by the use of cheaper materials and by the use of prefabricated sec tions or modules requiring a minimum use of labor in assembly.
Description of the prior art Most of the previous efforts in forming prefabricated panels involve the use of costly materials, such as wood and metal. The resulting panels are not only costly, but have poor sound and heat insulation properties, requiring not only the use of relatively thick sections to obtain the desired insulation properties, but also the use of additional heat insulation when used as exterior walls.
SUMMARY OF THE INVENTION It is an object of this invention, therefore, to provide novel prefabricated core structure for a prefabricated structural panel which overcomes the shortcomings of the prior art.
It is a further object to provide a novel prefabricated core structure and for a prefabricated structural panel having improved heat and sound insulation characteristics obtained by employing elongated nonmetallic tubing and members arranged to form a honeycomb unit.
[In brief, the invention comprises a novel prefabricated core structure for a prefabricated structural panel having filler material to form opposite parallel walls. The filler material may be selected from the conventional cementitious filler materials such as Portland cement, stucco, sand, gypsum plaster and the like, and may use large proportions of vermiculite or similar material if lightness in weight is a factor.
The core is made in the form of a honeycomb unit of a light material, such as polystyrene, marketed under various names such as Styrofoam, for example, and comprises a plurality of relatively short lengths of polystyrene in side-by-side relationship to form rows, and a series of rows arranged in tiers, the longitudinal axes of the short lengths of polystyrene in one row being laterally offset 3,516,59 Patented Nov. 2, 1971 relative to the longitudinal axes of the lengths in an adjoining row to produce the individual cells of the honeycomb unit. The rows and tiers are interconnected by a series of elongated tubing of plastic material or coated hard cardboard material. The tubing is disposed in vertical and horizontal rows passing through the individual lengths of the honeycomb unit to maintain them in assembled relation, and the individual tubes, comprising the tubing, are extended on each end beyond the honeycomb unit to the end of the panel when the core is embedded within a panel. The tubes are arranged in symmetrical form so that, when the panels are assembled in a wall and the like by conventional tongue and groove joints, the tubes in one panel axially align with those in an adjoining panel to form a continuous conduit through which Water pipes, electrical cable, and the like may be extended.
BRIEF DESCRIPTION OF THE DRAWING In order to obtain a clear understanding of the construction, method of manufacture, and use of the novel prefabricated core structure, reference is made to the detailed description which follows and to the accompanying drawing, in which:
FIG. 1 is an end view of a preferred form of my novel prefabricated core structure, illustrating the arrangement of parts forming the honeycomb unit and its position in a finished panel shown in broken lines; and
FIG. 2 is a top plan view of the construction of FIG. 1, illustrating, by the use of broken lines, a phantom prefabricated structural panel embodying the core structure.
DESCRIPTION OF A PREFERRED EMBODIMENT Referring to the accompanying drawing, showing the core structure in solid lines, the numeral .10 designates the core structure in its entirety embedded within a prefabricated structural panel 12 shown in phantom by the use of broken lines. The core structure 10 includes a honeycomb or cellular unit 14 made up of a plurality of elongated members 16 and half members 18. The members 16 and 18 can be made of any desired form in section, such :as circular, oval, elliptical, triangular, square, rectangular or other angular form, and are disposed in rows and in tiers to form a plurality of elongated cells 20 between them.
In the preferred embodiment illustrated in the drawing, the members 16 are hexagonal in cross section, as seen in FIG. 1, and are disposed in the rows I, II, III, IV and V. Each row includes a plurality of the members 16, arranged side-by-side in abutting relation, the angles or corners engaging in line contact. On each end of the rows numbered II and IV there is a member 18 in the form of one-half of a hexagon member 16. If desired, however, a full hexagonal member 16 may be used at these points.
The individual rows 1, II, III, IV and V are stacked in tiers as shown, with the upper angles or corners of one row or tier in line contact with the lower angles or corners of an adjacent row or tier. In this manner, the longitudinal axes of the members 16 in one row or tier are laterally offset relative to the longitudinal axes of the members 16 in an adjoining row or tier.
The members 16 and 18 can be made of any desired material, such as wood, metal, cardboard, plastic, etc., but it is preferred that they be solid and made of a plastic material, preferably polystyrene marketed under various names, such as Styrofoam, for example. This latter material is particularly adapted for a core structure in a panel, because it is light, has the desired strength for its purpose, is not affected by moisture or water, and has exceptionally low heat and sound conduction characteristics.
The members 16 and 18 are held in assembled relation by a plurality of tie rods forming a tubing system including a pair of vertically disposed tubular members 22 and 23, and first group comprising four horizontally disposed tubular members 24, 26, 28 and 30. As shown in FIGS. 1 and 2, the vertical tubular member 22 passes transversely through the mid portion of each of the left hand members 16 in the rows I, III and V, and through the right hand angles or corners of the half members 18 and through the left hand angles or corners of the adjacent members 18 in the rows II and IV. Similarly, the other vertical tubular member 23 passes transversely through the center of the right hand end members 16 of the rows I, III and V, and through the left hand angles or corners of the right hand half members 18 and through the right hand angles or corners of the adjacent members 16 in rows II and IV.
The horizontally extending tubular members 24, 26, 28 and 30 are disposed in pairs on opposite sides of the vertically extending tubular members 22 and 23, the tubular members 24 and 28 being in parallel relation and on one side of a plane passing through the longitudinal axes of the vertically extending tubular members 22 and 23, and the tubular members 26 and 30 being in parallel relation and on the other side of said plane. The three planes lying in the longitudinal axes of the tubular members 22 and 23, the tubular members 24 and 28, and the tubular members 26 and 30, therefore, are arranged in parallel, spaced, relation.
The horizontally extending tubular member 24 extends transversely through one end of the elongated members 16 of row I; the tubular member 26 extends transversely through the opposite ends of the elongated members 16 and half members 18 of row II; the tubular member 28 extends transversely through one end of the elongated members 16 and half members 18 of row IV, directly below the tubular member 24 in row I and through the same ends of the members 16; and the tubular member 30 extends transversely through the opposite ends of the elongated members 16 of row V, directly below the tubular member 26 in row II and through the same ends of the members 16. With this arrangement of tubular members, it is evident that at least one tubular member passes through each of the members 16 and 18, except for a few of the members in the middle of row III which are main tained in assembled relation by the adjoining members 16 in rows II and IV.
The tubular members 22, 23, 24, 26, 28 and 30 are shown in the drawings as extending beyond the honeycomb unit 14 to the ends of the structural panel 12, the latter being provided with tongues 32 and grooves 34 to facilitate assembly of a wall or other structural part. As is customary in panels, two adjoining edges have tongues while the other two adjoining edges have grooves. This arrangement of tongues and grooves provides a symmetrical structure wherein, in assembly, the longitudinal axes of the tubular members in one panel align with the longitudinal axes of the tubular members in an adjoining panel. The vertical tubular members 22 and 23 extend into the tongue 32, as seen in the upper part of FIG. 1, and terminate at the bottom of the groove 34 as seen in the lower part of the figure. The horizontal tubular members 24, 26, 28 and 30 terminate at the ends of the panel proper.
The prefabricated core structure can be incorporated into a structural panel 12 as follows:
A form of the desired size and shape can be used. Assuming a 4-inch thick panel, wherein the elongated members 16 and 18 are three inches long, one pours on the bottom of the form a layer one half inch thick of gravel or any filler material used, which is spread evenly. The prefabricated core structure 10 is deposited on this one-half inch thick layer so that the tubular members contact the sides of the form. Material may be inserted into the ends of the tubular members to keep out the filler material or any other foreign matter. As an alternative, the tubular members may be made longer than required in the finished panel, so that, when inserted in the form, the ends thereof extend outside the form in suitable holes provided in the sides of the form. Filler material is poured over the core structure 10 in the form, so that the material passes into and through the cells 20, until a 4-inch depth is attained, forming a solid layer one-half thick above the core. After the filler material has set, the finished panel is removed from the form, and the superfluous ends of the tubular members which extend beyond the panel are cut off.
The prefabricated core structure shown in the drawing is intended for a small finished panel, and therefore a relatively few elongated members 16 and 18 are used. It is evident that considerably more of such members, as well as more tubular members, are required for larger panels, assembled in the same manner.
It is intended to use this prefabricated core structure in the various sizes of panels employed in the industry.
When assembled in a finished wall and the like, the ends of the tubular members in one panel align with the ends of the ends of the tubular members in an adjoining panel, in axial alignment, thereby providing a structure through which pipes and electrical conduits and the like can readily be inserted.
I claim:
1. A prefabricated core structure for a prefabricated structural panel, comprising: a plurality of elongated members disposed in side-by-side relation to form a plurality of rows, each of said members being hexagonal in cross section to provide a plurality of corners, the elongated members in one row being disposed in abutting relation with the elongated members of adjacent rows to form a tiered unit, the longitudinal axes of the members in one row being laterally offset relative to the longitudinal axes of the members in an adjacent row, whereby the members in one row are in corner-to-corner contact with the members in an adjacent row, forming a honeycomb unit having a plurality of elongated separated cells of triangular cross section; and a plurality of tie rods passing through and interconnectin g said members into a single unit.
2. A prefabricated core structure as defined in claim 1, in which said tie rods comprise tubular members extending beyond said honeycomb unit to points corresponding to the ends of a structural panel when incorporated in a structural panel.
3. A prefabricated core structure for a prefabricated structural panel, comprising: a plurality of elongated members disposed in side-by-side relation to form a plurality of rows, each of said members being polygonal in cross section to provide a plurality of corners, the elongated members in one row being disposed in abutting relation with the elongated members of adjacent rows to form a tiered unit, the longitudinal axes of the members in one row being laterally offset relative to the longitudinal axes of the members in an adjacent row to provide a plurality of elongated cells; and a plurality of tie rods passing through and interconnecting said members into a single unit, sai dtie rods including a first group and a second group of tubular members, the members in one group being disposed substantially at right angles to the members of the other group, the tubular members in the first group passing through and interconnecting the ends of the elongated members, and the tubular members in the second group passing through and interconnecting the mid portions of the elongated members, said tubular members being disposed symmetrically with reference to a central plane parallel with one group of said tubular members and at right angles with the other group of said tubular members whereby, when a pair of structural panels including said core structure are placed in end-to-end relation, the longitudinal axes of the tubular members in one panel will align with the longitudinal axes of the tubular mem- FOREIGN PATENTS 111 the Panel- 908,084 1946 France 52-663 R f rence Cited 1,279,466 1961 France 5'2 615 e e S 905,399 1962 Great Britain 52228 UNITED STATES PATENTS 5 771 03 10 1904 Burnell 52 63 JOHN G P m y EXaminer 2,253,659 8/1941 Swarovski 52-663 2,800,688 7/1957 Lobel 52-663 52 309 615 664 2,980,971 4/1961 Furiness 160229
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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6711872B2 (en) 2001-07-30 2004-03-30 International Paper Company Lightweight panel construction
US6883590B1 (en) * 1998-11-23 2005-04-26 Plan Holding Gmbh Self-supporting, modular prefabricated radiating panel
US20090139689A1 (en) * 2006-09-20 2009-06-04 Doo Nyun Kim Side panel for heating room and construction process
US11283000B2 (en) 2015-05-14 2022-03-22 Nimbus Materials Inc. Method of producing a flexible thermoelectric device to harvest energy for wearable applications

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6883590B1 (en) * 1998-11-23 2005-04-26 Plan Holding Gmbh Self-supporting, modular prefabricated radiating panel
US6711872B2 (en) 2001-07-30 2004-03-30 International Paper Company Lightweight panel construction
US20090139689A1 (en) * 2006-09-20 2009-06-04 Doo Nyun Kim Side panel for heating room and construction process
US11283000B2 (en) 2015-05-14 2022-03-22 Nimbus Materials Inc. Method of producing a flexible thermoelectric device to harvest energy for wearable applications

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