WO2014209548A1 - Panneaux structuraux composites et composants - Google Patents

Panneaux structuraux composites et composants Download PDF

Info

Publication number
WO2014209548A1
WO2014209548A1 PCT/US2014/040753 US2014040753W WO2014209548A1 WO 2014209548 A1 WO2014209548 A1 WO 2014209548A1 US 2014040753 W US2014040753 W US 2014040753W WO 2014209548 A1 WO2014209548 A1 WO 2014209548A1
Authority
WO
WIPO (PCT)
Prior art keywords
inner core
composite panel
geometry
longitudinally extending
panel
Prior art date
Application number
PCT/US2014/040753
Other languages
English (en)
Inventor
Robert Noble
Original Assignee
Noble Environmental Technologies Corporation
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
Application filed by Noble Environmental Technologies Corporation filed Critical Noble Environmental Technologies Corporation
Publication of WO2014209548A1 publication Critical patent/WO2014209548A1/fr

Links

Classifications

    • 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
    • E04C2/3405—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 profiled spacer sheets
    • 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
    • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
    • E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
    • E04C2/521—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits serving for locating conduits; for ventilating, heating or cooling
    • 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
    • E04C2/3405—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 profiled spacer sheets
    • E04C2002/3411—Dimpled spacer sheets
    • E04C2002/3422—Dimpled spacer sheets with polygonal dimples
    • 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
    • E04C2/3405—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 profiled spacer sheets
    • E04C2002/3411—Dimpled spacer sheets
    • E04C2002/3427—Dimpled spacer sheets with conical dimples
    • 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
    • E04C2/3405—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 profiled spacer sheets
    • E04C2002/3444—Corrugated sheets
    • 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
    • E04C2/3405—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 profiled spacer sheets
    • E04C2002/3444—Corrugated sheets
    • E04C2002/345—Corrugated sheets with triangular corrugations
    • 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
    • E04C2/3405—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 profiled spacer sheets
    • E04C2002/3444—Corrugated sheets
    • E04C2002/3455—Corrugated sheets with trapezoidal corrugations
    • 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
    • E04C2/3405—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 profiled spacer sheets
    • E04C2002/3472—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 profiled spacer sheets with multiple layers of profiled spacer sheets
    • 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
    • E04C2002/3494—Apparatus for making profiled spacer sheets
    • 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
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • 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.]
    • Y10T428/24628—Nonplanar uniform thickness material
    • Y10T428/24661—Forming, or cooperating to form cells

Definitions

  • the present disclosure in its many embodiments, alleviates to a great extent the disadvantages of a high density traditional structural panels by providing a sandwich type of construction in which two planar skin layers are affixed to a central core of a specified geometry.
  • the central core serves to spatially separate the planar skin layers and in an embodiment also forms inner voids between portions of the inner core and/or portions of the inner core and a skin layer.
  • mechanical elements such as ducting, wiring or other elements may be positioned within the void spaces.
  • the voids may serve as fluid transit ducts such as for ventilation purposes.
  • a composite panel is formed from fiberboard material.
  • a bottom side of a first sheet and a top side of a second sheet are attached to an inner core forming the panel.
  • the inner core may have a liner geometry.
  • the linear geometry has a corrugated interior shape.
  • the inner core may also be comprised of discrete elements.
  • the discrete elements may be of any desired geometry, such as cones, overlapping pyramids, non-overlapping pyramids or longitudinally extending ridges.
  • the discrete elements may be aligned to form a longitudinally extending void from one end of the panel to the other. Electrical or mechanical conduits may be inserted into the longitudinally extending voids.
  • FIG. 1 is an elevation view of a panel in accordance with an embodiment of the invention
  • FIG. 2 is an elevation view of an inner core in accordance with the invention.
  • FIG. 3 is a perspective view of a panel in accordance with an embodiment of the invention.
  • FIG. 4 is a perspective view of an inner core in accordance with an embodiment of the invention.
  • FIG. 5 is a plan view of an element in accordance with an embodiment of the invention.
  • FIG. 6 is a perspective view of an element in accordance with an embodiment of the invention.
  • FIG. 7 A is a perspective view of an inner core in accordance with an embodiment of the invention.
  • FIG. 7B is a perspective view of an inner core in accordance with an embodiment of the invention.
  • FIG. 8A is a plan view of an inner core in accordance with an embodiment of the invention.
  • FIG. 8B is a cross-sectional view taken along line 5-5 in FIG. 8A of an inner core in accordance with an embodiment of the invention.
  • FIG. 8C is a cross-sectional view of an inner core in accordance with an embodiment of the invention.
  • FIG. 9A is a perspective view of an inner core with an embodiment of the invention.
  • FIG. 9B is a detail perspective view of an inner core in accordance with an embodiment of the invention.
  • FIG. 9C is a cross-sectional view taken along line 5-5 in FIG. 9B of an inner core in accordance with an embodiment of the invention.
  • FIG. 1 OA is a perspective view of an inner core in accordance with an embodiment of the invention.
  • FIG. 10B is a detail perspective view of an inner core in accordance with an embodiment of the invention.
  • FIG. IOC is a top plan view of an inner core in accordance with an embodiment of the invention.
  • FIG. 10D is a cross-sectional view taken along line 5-5 in FIG. IOC of an inner core in accordance with an embodiment of the invention.
  • FIG. 11 A is a perspective view of an inner core in accordance with an embodiment of the invention.
  • FIG. 1 IB is a detail perspective view of an inner core in accordance with an embodiment of the invention.
  • FIG. l lC is a perspective view of an element of an inner core in accordance with an embodiment of the invention.
  • FIG. 1 ID is a cross-sectional view taken along lines 5-5 and 6-6 in FIG. 1 IB of an inner core in accordance with an embodiment of the invention.
  • FIG. 12 is a perspective view of a panel in accordance with an embodiment of the invention.
  • FIG. 13 is a perspective view of a panel in accordance with an embodiment of the invention.
  • FIG. 14 is a perspective view of a panel in accordance with an embodiment of the invention.
  • FIG. 15 is a perspective view of a panel in accordance with an embodiment of the invention.
  • FIG. 16 is a perspective view of a panel in accordance with an embodiment of the invention.
  • FIG. 1 An example of a panel 10 is illustrated in FIG. 1.
  • the panel 10 has an inner core 20 of a predetermined geometry, a first sheet or skin 30, which is illustrated as a top sheet, and a second sheet or skin 40, which is illustrated as a bottom sheet.
  • a first sheet or skin 30 which is illustrated as a top sheet
  • a second sheet or skin 40 which is illustrated as a bottom sheet.
  • one of the sheets 30, 40 may be oriented towards the inside of a room and the other one of the sheets 30, 40 may be oriented towards either the inside of a two panel wall, or the inside of an adjacent room or the exterior of a structure.
  • Each of the sheets 30, 40 has an inner surface 32, 42 oriented toward the interior of the panel 10, and an outer surface 34, 44 oriented toward the exterior of the panel 10.
  • any structure and geometry may be selected for inner core 20 in the present invention that achieves desired structural characteristics, such as stiffness, strain resistance and interior voids creation.
  • the terms “skins” or “sheets” are being used for naming purposes only and not for purposes of limitation, as are the terms “top sheets” and “bottom sheets.”
  • the inner core geometry forms plural longitudinally extending interior voids 120 between walls 25 of the inner core 20 geometry and the inner surfaces 32 and /or 42 of one or more of the sheets 30, 40.
  • the panel 10 and its components, such as the sheets 30, 40 and core 20 may be formed of any materials that will impart the physical properties and structural integrity desired. Examples of some materials these components include cardpanel, paperpanel, wood, cellulosic composites, compressed cellulose material blends, brass, stainless steel, or other metals, polymeric materials or other cellulosic based products, or combinations of these materials. Some examples of suitable molded and/or compressed cellulose based materials are discussed in commonly owned United States Patent No. 8,297,027, entitled, "Engineered Molded Fiberboard Panels and Methods of Making and Using the Same" and United States Patent No.
  • inner core 20 has a wave or corrugated structure.
  • the corrugated structure features angled flanges 50 positioned between alternating peaks 60.
  • the top and bottom skins (not shown in FIG. 2) are affixed to the respective alternating peaks 60.
  • the top and bottom skins are affixed to their respective peaks 60 by an adhesive layer. Any suitable adhesive may be selected that provides a desired level of adhesion, heat expansion or contraction, longevity etc. between the peaks 60 and the top and bottom skins.
  • FIGS. 3 and 4 Two general examples of suitable geometries for the inner core 20 are shown in FIGS. 3 and 4.
  • FIG. 3 illustrates a panel with a linear geometry in its inner core.
  • FIG. 4 illustrates an inner core with a discrete geometry.
  • a cross-sectional profile exceeds the length of panel 10.
  • the inner core geometry extends from one end of panel 100 to the other end of panel 110.
  • the space between the inner core and the top and bottom skins form void spaces. These void spaces are longitudinally extending voids 120 spanning from one end 100 to the other end 110.
  • FIG. 4 Shown in FIG. 4 is a discrete geometry.
  • the inner core includes parallel discrete elements 27.
  • a discrete element 27 has a peak 28 bordered by axially extending side walls 29.
  • the angle and dimensions of the sidewalls 29 and the dimensions of the peaks 28 may vary to form different discrete geometries.
  • FIGS. 5 and 6 Two examples of possible discrete geometries that can be achieved through the present invention are shown in FIGS. 5 and 6.
  • the discrete element 27 in FIG. 5 has a broad peak 28 with acute angled, small sidewalls 29.
  • the discrete element 27 in FIG. 6 has a narrow peak 28 with acute angled, long sidewalls 29.
  • the discrete element 27 in FIG. 5 has a box-like shape, whereas the discrete element 27 in FIG. 6 has a pyramid-like shape.
  • FIGS. 7 through 11 illustrate some of the many embodiments of the inner core 20 provided by the present invention. Shown in these Figures are perspective views, detailed perspective views, plan views, detailed plan views and elemental perspective views of the inner core embodiments. Generally, as described earlier, top and bottom skins sandwich the inner core. For illustration purposes, these skins are not illustrated in FIGS. 7 through 11.
  • FIGS. 7 A and 7B show a perspective view and a detailed perspective view of inner core 20.
  • this embodiment has a linear geometry with a corrugated structure 50, 60.
  • the linear feature of this embodiment spans from end 100 of corrugated inner core 20 to the opposing end 110 of corrugated inner core 20.
  • open space 120 defining longitudinally extending voids are formed between the inner core and the skins.
  • mechanical or electrical elements may be positioned within one or more of the longitudinally extending void spaces 120 of this embodiment.
  • mechanical or electrical elements may include ventilation ducts, wires, lighting, cables, plumbing or conduits.
  • the void spaces provide a protected conduit through the panel.
  • the electrical or mechanical element need not pass through the entire longitudinally extending void space but may terminate at any point in the void 120.
  • FIG. 8 A is a plan view of the corrugated inner core 20 of this embodiment.
  • FIGS. 8B and 8C are a cross sectional view and a detailed cross sectional view of the corrugated structure.
  • the corrugated elemental features have angled flanges 50 positioned between alternating peaks or surfaces 60. It should be understood that the angles of the flanges can vary. Sharper angles or more obtuse angles are possible. It should be further understood that the lengths of the alternating peaks or surfaces can vary. By adjusting the angles of the flanges 50 and the lengths of the peaks 60, multiple embodiments of longitudinally extending voids 120 derived from a corrugated wave structure are possible.
  • voids may be constructed by providing an obtuse angle with larger peaks. It should be appreciated that by increasing the width of the longitudinally extending voids, the number of voids per panel is decreased. Increased widths of the void spaces allow for the passage of larger mechanical or electrical instrumentalities.
  • the widths of the void spaces may be decreased by shortening the lengths of peaks 60 and decreasing the angles of the angled flanges 50. It should be appreciated that by decreasing the size of the void spaces, the number of voids per panel is increased. Increasing the number of voids per panel allow for increased electrical or mechanical conduits. In addition, because the longitudinally extending voids are isolated from each other, additional insulation to electrical or mechanical instrumentality inside the void is provided. It should also be appreciated that both small and large voids may be implemented within the same panel, if that is a desirable feature. [0050] FIGS. 9 through 11 disclose embodiments with discrete elements in the inner core. FIGS.
  • FIG. 9 A and 9B are a perspective view and a detailed perspective view of an inner core 80 featuring a discrete element.
  • element 200 of inner core 80 has a pyramidlike structure with peaks 28 bordered by axially extending sidewalls 29.
  • this structure will be referred to as a pyramidal embodiment.
  • the pyramidal embodiment features a discrete element in the shape of a pyramid 200 that is not continuous for the length of the panel, such as the inner core in the embodiments illustrated in FIGS. 7-8
  • the pyramidal discrete elements 200 may be aligned in parallel rows such that open spaces defining longitudinally extending voids span from one end 100 of panel 80 to opposite end 110.
  • electrical and mechanical elements may be inserted into the longitudinally extending void spaces. The electrical or mechanical element need not pass through the entire longitudinally extending void space but may terminate at any point in the void 120.
  • FIGS. 9C is a cross sectional view of the pyramidal embodiment of FIGS. 9A-9B.
  • the cross section shows a corrugated structure with angled sidewalls 29 alternating between peaks 28.
  • the void spaces in the pyramidal embodiment structure can be varied in width and height. Sharper angles or more obtuse angles between the sidewalls 29 and peaks 28 are possible. It should be further understood that the lengths of the alternating peaks 28 are variable. By adjusting these features, multiple embodiments of longitudinally extending voids derived from discrete elements 200 in the inner core 20 are possible. Larger voids may be constructed by providing an obtuse angle between sidewalls 29 and peaks 28.
  • voids are also made possible by increasing the length of the peaks 28. Smaller voids may be constructed by decreasing the angle between sidewalls 29 and peak 28. Smaller voids are also made possible by decreasing the length of peaks 28. By increasing the size of the void spaces, there will be less voids per panel. By decreasing the size of the void spaces, there will be more voids per panel.
  • the number and size of the longitudinally extending voids 120 are dependent upon the characteristics of the electrical or mechanical elements to be inserted into them. It should be further appreciated that both small and large voids may also be implemented within the same panel 10, if that is a desirable feature.
  • FIGS. 10A and 10B illustrate another embodiment of inner core featuring discrete elements 300 with a conical geometry.
  • FIG. 10B is a detailed perspective view of the discrete element 300.
  • Conical discrete element 300 is formed by peaks 360 bordered by axially extending rounded sidewalls 350.
  • this structure will be referred to as a conical embodiment.
  • the conical embodiment of FIGS. 10A- 10B has a discrete element 300 that is not continuous for the length of the panel, the conical discrete elements 300 may be aligned in parallel rows such that open spaces defining longitudinally extending voids span from one end 100 of panel 10 to the opposite end 110.
  • electrical and mechanical elements may be inserted into the longitudinally extending void spaces. The electrical or mechanical element need not pass through the entire longitudinally extending void space but may terminate at any point in the void 120.
  • FIG. IOC shows a plan view and FIG. 10D shows a cross sectional view of the conical embodiment.
  • the cross section depicts a semi-corrugated structure with peaks 360 bordered by axially extending rounded sidewalls 350.
  • the void spaces in the conical embodiment structure may be varied in width and height. Sharper angles or more obtuse angles between rounded sidewalls 350 and peaks 360 are possible. It should be further understood that the lengths of the peaks 360 are variable. By adjusting the angles of the sidewalls and the lengths of the peaks, multiple embodiments of longitudinally extending voids are possible.
  • Larger voids may be constructed by increasing the angle between the rounded sidewall 350 and peak 360. Larger voids may also be constructed by increasing the size of peaks 360. Smaller voids may be constructed by decreasing the angle between the rounded sidewall 350 and peak 360. Smaller longitudinally extending voids may also be constructed by decreasing the size of peaks 360. An increase in the size of the void spaces results in less voids per panel. Conversely, decreasing the size of the void spaces results in more voids per panel. The number and size of the longitudinally extending voids 120 is dependent upon the characteristics of the electrical or mechanical elements inserted into them. It should be further appreciated that both small and large voids may also be implemented within the same panel, if that is a desirable feature.
  • FIGS. 11 A through 1 ID Another possible shape for an inner core discrete element is shown in FIGS. 11 A through 1 ID.
  • the discrete element 400 is hexagonally or egg-crate shaped with four axially extending sidewalls 410 surrounding peak and valley surfaces 420.
  • this structure will be referred to as a hexagonal embodiment.
  • the open space between the inner core 95 and the top and bottom skins 30, 40 of the hexagonal embodiment does not define a longitudinally extending void.
  • the hexagonal embodiment has a more undulated inner core than the previously disclosed embodiments.
  • the hexagonal embodiment's increased undulation provides the panel with greater insulating characteristics.
  • a variety of embodiments are possible by either increasing or decreasing the number and/or arrangements of skins 30, 40 or the number and/or arrangements of inner cores 20 or both.
  • a panel may be created without one or both of the top and bottom skins 30, 40. Illustrated in FIG. 12 is an embodiment of a panel 10 with two inner cores stacked on top of one another.
  • Each of the inner cores 80 has a discrete element geometry 200 of the pyramidal embodiment shown in FIGS. 9A-9B.
  • the top inner core 80 is flipped upside down and affixed onto the top of the bottom inner core 80. It should be appreciated that by stacking the top inner core 80 upside down on top of the bottom inner core 80, taller longitudinally extending void spaces 120 may be produced.
  • Taller voids 120 are adaptable to larger electrical and mechanical elements being inserted into them.
  • first and second skin layers 30, 40 may also be included in this embodiment. It also should be noted that in the embodiments discussed herein where skins 30, 40 are not provided, although the structures shown are referred to as "inner core,” for purposes of continuity with the description of other embodiments, in the non-skin embodiments, surfaces of the inner cores 20 are exposed.
  • FIG. 13 shows another embodiment of a panel 10, including inner cores 20 in stacked relation to one another. Similar to the embodiment shown in FIG. 12, top and bottom skins 30, 40 are not included, but optionally in an alternative embodiment, they can be included.
  • Each of the inner cores 20 has a linear geometry with the one of the inner cores rotated with respect to the other. In the illustrated embodiment, the first or top inner core 20 is rotated 90 degrees relative to the second or bottom inner core 20. Longitudinally extending void spaces 120 are provided in both the x and the y directions. Optionally, electrical and mechanical elements may be routed in either direction through the longitudinally extending voids 120.
  • the electrical or mechanical element need not pass through the entire longitudinally extending void space but may terminate at any point in the void 120. It should be appreciated that this embodiment provides an increased number of void spaces.
  • additional layers of inner cores 20 may be added.
  • four stacked inner core layers 20 are provided.
  • the top and bottom inner cores 200 and 215 are orientated in the same direction, and the two middle inner cores 205 and 210 are rotated 90 degrees relative to the top and bottom inner cores 200, 215.
  • the two middle layers are stacked with their peaks touching, and optionally affixed to one another, for example using adhesive or mechanical fasteners, as in other embodiments where layers of inner cores are positioned adjacent to one another.
  • Longitudinally extending void spaces 120 are provided in both the x and y directions.
  • longitudinally extending void spaces 120 in the x direction are formed between the bottom layer 215 and one of the middle layers 210 and also between the top layer 200 and inner layer 205.
  • longitudinally extending void spaces 120 in the y direction are formed between the two middle layers 205, 210.
  • additional inner core layers it is possible to add additional inner core layers to the embodiment shown in FIG. 14.
  • another two layers arranged like layers 205 and 210 are with respect to each other may be positioned adjacent the free side of layer 200, or layer 215. Additional inner core layers will add thickness to the panel and provide additional longitudinally extending voids.
  • multiple inner core layers 20 are provided with skin layers 30 and/or 40.
  • FIG. 15 illustrates an embodiment corresponding to that of FIG. 13, but with first and second skins 30, 40 included.
  • FIG. 16 illustrates an embodiment corresponding to that of FIG. 16, but with first and second skins 30, 40 included.
  • liner geometry inner cores are layered on discrete element geometry inner cores with skins separating the inner cores. It should be appreciated that any combination and number of inner cores may be included in a composite structural panel depending upon the design specifications and desirable features.
  • the panels are lightweight because of their low-density inner cores. Thus, the panels may be sized so that they can be easily loaded, unloaded and assembled by no more than two people. Due to their light weight, the panels are easily transportable. A pick-up truck can carry a load of panels to remote and isolated locations for easy assembly and disassembly. Further, the panels are fully recyclable and reusable. They can be disassembled and reused at another location.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention se rapporte à des panneaux composites qui comportent des couches de cœur présentant une géométrie particulière, ainsi qu'une première et une seconde couche de revêtement facultatives. Les composants sont composés facultativement d'un matériau de panneau de fibres. Soit le cœur présente une géométrie linéaire, soit il est composé d'éléments séparés. Selon des modes de réalisation donnés à titre d'exemple, des vides s'étendant longitudinalement s'étendent à travers le panneau. Des conduits électriques ou mécaniques peuvent être insérés à travers les vides s'étendant longitudinalement.
PCT/US2014/040753 2013-06-28 2014-06-03 Panneaux structuraux composites et composants WO2014209548A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US201361841237P 2013-06-28 2013-06-28
US61/841,237 2013-06-28
US14/295,169 2014-06-03
US14/295,169 US20150004371A1 (en) 2013-06-28 2014-06-03 Composite structural panels and components

Publications (1)

Publication Number Publication Date
WO2014209548A1 true WO2014209548A1 (fr) 2014-12-31

Family

ID=52115862

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2014/040753 WO2014209548A1 (fr) 2013-06-28 2014-06-03 Panneaux structuraux composites et composants

Country Status (2)

Country Link
US (1) US20150004371A1 (fr)
WO (1) WO2014209548A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150004371A1 (en) * 2013-06-28 2015-01-01 Noble Environmental Technologies Corporation Composite structural panels and components

Families Citing this family (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013188967A1 (fr) * 2012-06-21 2013-12-27 Pantero Technologies Inc. Cadre de châssis plat pour structure de véhicule et logement de pièces
US9284726B2 (en) * 2014-04-04 2016-03-15 The Boeing Company Pyramid waffle core structure and method of fabrication
CA3126665C (fr) * 2014-10-02 2023-04-18 Composites Intellectual Holdings, Inc. Panneau structural composite et methode de fabrication
US10286623B2 (en) * 2015-06-15 2019-05-14 Lockheed Martin Corporation Composite materials with tapered reinforcements
FI20165168A (fi) * 2016-03-02 2017-09-03 New Invest Oy Laattaelementti, alapohja ja menetelmä alapohjan rakentamiseksi
EP3272480B1 (fr) * 2016-07-21 2022-12-07 Homann Holzwerkstoffe GmbH Procédé de fabrication d'un panneau de fibres
US20200332528A1 (en) * 2018-01-08 2020-10-22 Francisco Javier FERNANDEZ HERRERO Resistant modular hollowed-out plate for manufacturing slabs
US10837174B2 (en) 2018-05-21 2020-11-17 Donald Doll Insulating wall panels for building construction and related methods
IT201800006605A1 (it) * 2018-06-25 2019-12-25 Procedimento per la produzione di una lastra a profilo grecato in materiale termoplastico e relativa apparecchiatura.
US11794927B2 (en) * 2019-08-28 2023-10-24 The Boeing Company Additively manufactured spacecraft panel
US11542041B2 (en) 2020-05-18 2023-01-03 The Boeing Company Additively manufactured satellite panel with damping
US11827389B2 (en) 2020-05-18 2023-11-28 The Boeing Company Additively manufactured satellite
SE545285C2 (en) * 2022-02-23 2023-06-20 Wahlberg Ventigolv AB A diffuser component, a system and methods for floor displacement ventilation

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5900304A (en) * 1997-03-13 1999-05-04 Owens; Thomas L. Molded wood fiber web and structural panels made utilizing the fiber web
US6511567B1 (en) * 1999-03-31 2003-01-28 International Paper Company Composite building components and method of making same
US20050138879A1 (en) * 2003-10-10 2005-06-30 Unda Maris B.V. Flat wall panel at least substantially made of cellulose material
US20070020441A1 (en) * 2005-07-22 2007-01-25 Hongseong Industrial Co., Ltd Core for a sandwich panel manufactured by deep drawing and a sandwich panel thereby
US8297027B2 (en) * 2008-03-28 2012-10-30 The United States Of America As Represented By The Secretary Of Agriculture Engineered molded fiberboard panels and methods of making and using the same

Family Cites Families (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1024889A (fr) * 1950-09-25 1953-04-08 Perfectionnements aux panneaux composites creux
US3086899A (en) * 1956-05-04 1963-04-23 Dow Chemical Co Constructional lamina
GB2035895A (en) * 1978-10-12 1980-06-25 Rushton M Board structure
US4495237A (en) * 1983-06-10 1985-01-22 Patterson Fred R Pyramidal core structure
US5487344A (en) * 1994-01-07 1996-01-30 Miriam M. Benson Block pallet construction using corrugated sheet materials
US5958551A (en) * 1995-08-31 1999-09-28 Garcia-Ochoa; Jorge-Isaac Structural element
US5894045A (en) * 1996-11-12 1999-04-13 Desrondiers; Bernard R. Cellular core structure building component
JPH10166481A (ja) * 1996-12-17 1998-06-23 Hideo Yugawa パネル芯材
US7954446B2 (en) * 2005-01-27 2011-06-07 Trinity Industrial Corporation Hopper for cleaning coating machine
JP2006305999A (ja) * 2005-04-27 2006-11-09 Hideo Yugawa サンドイッチパネル
US20090038650A1 (en) * 2007-08-10 2009-02-12 Ronald Grogan Compositions and substrate cleaning methods
US8549407B2 (en) * 2007-12-05 2013-10-01 Ebay Inc. Multi-dimensional dynamic visual browsing
EP2456618B1 (fr) * 2009-07-22 2017-09-06 Straza, George C.P. Structures sandwich à âme formée
US20150004371A1 (en) * 2013-06-28 2015-01-01 Noble Environmental Technologies Corporation Composite structural panels and components

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5900304A (en) * 1997-03-13 1999-05-04 Owens; Thomas L. Molded wood fiber web and structural panels made utilizing the fiber web
US6511567B1 (en) * 1999-03-31 2003-01-28 International Paper Company Composite building components and method of making same
US20050138879A1 (en) * 2003-10-10 2005-06-30 Unda Maris B.V. Flat wall panel at least substantially made of cellulose material
US20070020441A1 (en) * 2005-07-22 2007-01-25 Hongseong Industrial Co., Ltd Core for a sandwich panel manufactured by deep drawing and a sandwich panel thereby
US8297027B2 (en) * 2008-03-28 2012-10-30 The United States Of America As Represented By The Secretary Of Agriculture Engineered molded fiberboard panels and methods of making and using the same

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150004371A1 (en) * 2013-06-28 2015-01-01 Noble Environmental Technologies Corporation Composite structural panels and components

Also Published As

Publication number Publication date
US20150004371A1 (en) 2015-01-01

Similar Documents

Publication Publication Date Title
US20150004371A1 (en) Composite structural panels and components
AU2006313679B2 (en) Method for manufacturing of cellular board, cellular board, method for producing cellular board element of steel plate strip, and production line
JP6461487B2 (ja) 折曲コアパネル
US2001632A (en) Insulation against losses of heat and cold
WO2009121016A3 (fr) Panneaux usinés de fibres moulées, procédés de réalisation de ceux-ci et produits fabriqués à partir de ces panneaux
EP2188077B1 (fr) Structure à panneaux
USH1481H (en) Offset corrugated sandwich construction
US20140134394A1 (en) Void containing structural member
US20160325530A1 (en) Industrial products engineered from processed bamboo or vegetable cane
EP2824251A2 (fr) Structure de kagome pyramidale et son procédé de fabrication
DE102005037055A1 (de) Flexibel formbare Kernstruktur für die Sandwichbauweise
EP2759470A3 (fr) Structure de boîte pour le support de charges et procede pour sa fabrication
NL2009760B1 (en) Strip of multilayer insulating product and strip of insulating complex made from such strips of multilayer insulating product.
WO2015012692A1 (fr) Élément de construction allongé
US20090022959A1 (en) Wall Element
US11162253B2 (en) Laminate cell construction system
US9169644B2 (en) Transparent structural element for covers
US20160052223A1 (en) Profile Based Structural Material Core, Structural Material and Production Method
CN107726035B (zh) 一种手风琴式蜂窝结构
US20100218437A1 (en) n-fold Hyperbolic Paraboloids and Related Structures
JP2008008364A5 (fr)
JP3298782B2 (ja) 緩衝用ハニカムコアおよびその製造方法
AU2014361132B2 (en) Wall element
AU2011253543B2 (en) System and Method for Manufacturing Cellular Board
US3076302A (en) Laminated filter

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 14817121

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 14817121

Country of ref document: EP

Kind code of ref document: A1