U.S. patent application number 11/854361 was filed with the patent office on 2009-03-12 for multi-layer construction panel system.
Invention is credited to John H. Baker, Peter M. Carlson, Michael W. Ishler.
Application Number | 20090064612 11/854361 |
Document ID | / |
Family ID | 40430366 |
Filed Date | 2009-03-12 |
United States Patent
Application |
20090064612 |
Kind Code |
A1 |
Carlson; Peter M. ; et
al. |
March 12, 2009 |
MULTI-LAYER CONSTRUCTION PANEL SYSTEM
Abstract
A construction panel system formed of a first, substrate panel
with a perimeter rim, a number of second panels, and attachments
for attaching the number of second panels and the first, substrate
panel in a spaced apart orientation to form a construction panel.
The perimeter rim on the first, substrate panel is used to attach a
number of construction panels to each other and to other
structures.
Inventors: |
Carlson; Peter M.; (La
Crescenta, CA) ; Ishler; Michael W.; (Santa Monica,
CA) ; Baker; John H.; (Venice, CA) |
Correspondence
Address: |
CHRISTIE, PARKER & HALE, LLP
PO BOX 7068
PASADENA
CA
91109-7068
US
|
Family ID: |
40430366 |
Appl. No.: |
11/854361 |
Filed: |
September 12, 2007 |
Current U.S.
Class: |
52/282.2 ;
52/282.3 |
Current CPC
Class: |
E04B 9/04 20130101 |
Class at
Publication: |
52/282.2 ;
52/282.3 |
International
Class: |
E04B 1/38 20060101
E04B001/38 |
Claims
1. A construction panel system, comprising: a first, substrate
panel; and at least one second panel; and attachments for attaching
the at least one second panel and the first, substrate panel in a
spaced apart orientation to form a construction panel.
2. The construction panel system of claim 1, wherein the spaced
apart orientation of the first, substrate panel and the at least
one second panel form an air space therebetween.
3. The construction panel system of claim 1, wherein the first,
substrate panel has a perimeter rim for use in attaching two or
more construction panels together or to other structures.
4. The construction panel system of claim 1, wherein the first,
substrate panel is formed of material selected from the group
consisting of fiberglass, polymers, composite plastics, metal,
plywood, composite wood products, and composite materials.
5. The construction panel system of claim 1, wherein the at least
one second panel is formed of material selected from the group
consisting of aluminum, steel, stainless steel, titanium, plastics,
wood, paper, composite materials, and resins.
6. The construction panel system of claim 1, wherein a plurality of
generally polygonal second panels are provided for each first,
substrate panel.
7. The construction panel system of claim 6, wherein the plurality
of generally polygonal second panels are generally triangular.
8. The construction panel system of claim 6, wherein the plurality
of generally polygonal second panels are spaced apart from each
other.
9. The construction panel system of claim 1, wherein the
attachments are selected from the group consisting of nuts and
bolts, posts, and adhesives.
10. The construction panel system of claim 3, wherein a plurality
of the construction panels are attached together by connecting the
construction panels along their respective rims.
11. The construction panel system of claim 1, wherein a plurality
of the construction panels are attached together by connecting the
construction panels along their respective rims.
12. The construction panel system of claim 1, wherein material is
placed between the first, substrate panel and the at least one
second panel.
13. The construction panel system of claim 1, wherein material is
fire retardant material.
14. A construction panel system, comprising: a first, substrate
panel having a perimeter rim; and a plurality of second generally
polygonal panels; and attachments for attaching the plurality of
second panels and the first, substrate panel in a spaced apart
orientation to form a construction panel.
15. The construction panel system of claim 14, wherein the first,
substrate panel is formed of material selected from the group
consisting of fiberglass, polymers, and composite plastics,
plywood, composite wood products, and composite materials.
16. The construction panel system of claim 14, wherein the at least
one second panel is formed of material selected from the group
consisting of aluminum, steel, stainless steel, titanium, plastics,
wood, paper, composite materials, and resins.
17. The construction panel system of claim 14, wherein a plurality
of the construction panels are attached together by connecting the
construction panels along their respective rims.
18. The construction panel system of claim 14, wherein the spaced
apart orientation of the first, substrate panel and the plurality
of second panels form air spaces therebetween.
19. The construction panel system of claim 14, wherein the
plurality of generally polygonal second panels are spaced apart
from each other.
20. The construction panel system of claim 14, wherein fire
retardant material is placed located between the first, substrate
panel and the at least one second panel.
Description
BACKGROUND
[0001] The invention relates to construction panels, and more
particularly to a construction panel formed of at least two layers
that are spaced apart from each other.
[0002] Construction panels are known in the home and commercial
construction industries. For example, there are panels that have
plywood as an outer layer, an internal framework of supporting
studs, plasterboard as an inner layer, insulation material
sandwiched between the outer and inner layers, and passages for
electrical and communications conduits. These prefab construction
panels systems are sometimes used to allow for faster building.
[0003] Suspended ceiling systems are also well-known in commercial
construction, wherein a series of T-shaped rails are suspended by
wires in a grid pattern, with the openings in the grid being
occupied by lightweight fiber panels, lighting fixtures, and the
like. These suspended ceiling systems, however, are adapted to form
flat ceilings and do not provide for much visual interest.
[0004] There accordingly remains a need for a construction panel
that permits great flexibility and visual interest in wall and
ceiling construction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a top view of a single construction panel of the
invention.
[0006] FIG. 2 is a top view of an exemplary embodiment of a series
of construction panels of the invention assembled into a larger
unit.
[0007] FIG. 3 is a cross-sectional view showing an exemplary
embodiment of construction panels of the invention attached
together.
[0008] FIG. 4 is a cross-sectional view showing an exemplary
embodiment of an attachment for holding a first, substrate panel
together with a second panel in a spaced-apart manner.
DETAILED DESCRIPTION OF THE INVENTION
[0009] Turning first to FIG. 1, there is shown a top view of an
exemplary embodiment of a construction panel 10 of the invention
(shown here as a generally triangular-shaped panel). These
construction panels 10 can be used to form interior walls and
ceilings in buildings and other structures including pavilions.
Each construction panel 10 has a first, substrate panel 12 which
functions as a base portion, and at least one second panel 14,
which functions as a skin portion which is attached to the first,
substrate panel 12 in a spaced apart manner. The first, substrate
panel 12 can be formed of materials such as fiberglass,
injection-molded plastic, polymers, composite plastics, metal and
the like. The at least one second panel 14 is preferably formed of
metal such as stainless steel, titanium, aluminum or other
materials, but other materials such as plastic, wood, paper, and
composite materials and the like can be used. Gaps 22 can
preferably be left between edges 38 of the adjacent second panels
14 in a construction panel 10, as shown in FIG. 3.
[0010] Turning to FIG. 2, there is shown a top view of an exemplary
embodiment of a series of construction panels 10A, 10B, 10C, 10D,
10E, and 10F of the invention (shown here as triangular-shaped
panels) that have been attached together, e.g. by bolts, rivets,
welding, adhesive, etc., to form a larger panel structure 20 with
the gaps 22 formed between the second panels 14 and with gaps 36
between the construction panels 10A, 10B, 10C, 10D, 10E, and 10F.
These gaps 22 and 36 can have the same or different widths, as
desired. The construction panels 10A, 10B, 10C, 10D, 10E, and 10F
and larger panel structure 20 can be used to form interior walls
and ceilings in buildings and other structures including pavilions.
In the case of the larger panel structure 20 being used as a
ceiling structure, people looking up will see the generally
triangular second panels 14 through the gaps 22 and 36. The
construction panels 10A, 10B, 10C, 10D, 10E, and 10F are shown
attached together into a generally hexagonal shaped structure.
However, the construction panels 10A, 10B, 10C, 10D, 10E, and 10F
can be configured to have a wide variety of shapes and sizes to
allow them to be used in a wide range of applications. For example,
the construction panels can be polygonal in general, e.g.,
rectangular, hexagonal, can have straight or curved sides, can be
formed flat or can have curvature, and can be other shapes.
[0011] FIG. 3 is a cross-sectional view showing parts of an
exemplary embodiment of a construction panel 10A of the invention
attached to a partial view of a second construction panel 10B. Each
construction panel 10A and 10B has a first, substrate panel 12
which functions as a base portion, and at least one second panel
14, and preferably a plurality of second panels, which functions as
a skin portion which is attached to the first, substrate panel 12
in a spaced apart manner. The first, substrate panel 12 can be
formed of materials such as fiberglass, injection-molded plastic,
polymers, composite plastics, metal, plywood, composite wood
products, other composite materials and the like. The at least one
second panel 14 is preferably formed of metal such as steel,
stainless steel, titanium, aluminum or other materials, but other
materials such as plastic, wood, paper, and composite materials and
the like can be used. Spacers 16 are used to space the at least one
second panel 14 apart from the first, substrate panel 12, thereby
creating an air space 18. Besides creating a certain visual
appearance in open seam areas 22 between individual second panels
14 and the underlying first, substrate panel 12, these air spaces
18 can also help increase the fire retardancy of the construction
panels 10 overall. The spacers 16 can comprise metal studs or other
attachments that join the first, substrate panel 12 to the second
panel 14. To permit two or more construction panels 10 to be
connected together, the first, substrate panel 12 can be provided
with a perimeter rim 30. Besides providing an attachment point for
two or more construction panels 10A, 10B and 10C, the perimeter rim
30 will give the first, substrate panel 12 greater constructional
integrity and resistance to flexing. The construction panels can be
attached together along their perimeter rims 30, e.g., by nuts and
bolts 32. However, rivets, adhesive, and other methods of
attachment can be used. For ease of assembly, holes 34 can be
provided at predetermined positions along the perimeter rim 30. The
second panels 14 can be sized and shaped such that when attached to
the first, substrate panel 12, that gaps 36 remain between
perimeter edges 38 of adjacent second panels 14. These gaps 36 can
add visual interest to construction panels and can allow the
substrate panel to be observed. The gap widths can be adjusted to
be as narrow or wide as desired, or, can be filled with other
structures, such as H-shaped inserts (not shown), which may be
formed of expanded wire or other shapes and/or materials, if
desired.
[0012] The construction panels 10 can be made to be generally flat
or can have curvature, with the material, size and color of the
first, substrate panel 12 and the second panels 14 selected based
on aesthetic and other requirements. The second panels 14 can be
flat or can also have curvature, texture or the like to create a
desired visual appeal. Also, the number of second panels 14 per
first, substrate panel 12 can be selected based on aesthetic and
other design considerations. Between the construction panels,
sealing means such as sealant material or gaskets 40 (as shown in
FIG. 3) can be used if desired to provide for improved
waterproofing and weatherproofing.
[0013] FIG. 4 is a cross-sectional detail view showing an exemplary
embodiment of an spacer 16 for holding a first, substrate panel 12
together with a second panel 14 in a spaced-apart manner to create
an airspace 18 therebetween. The spacers 16 can comprise, for
example, a number of metal studs 42 affixed (e.g. welded) to a
lower surface 44 of the second panels 14. The stud 42 can have a
threaded end 46 which will be passed through a hole 48 in the
first, substrate panel 12. A separator 50 will be located on the
stud 42 between the second panels 14 and the first, substrate panel
12. A washer 52 will preferably be placed on an upper surface 54 of
the first, substrate panel 12 and a nut 56 threaded onto the
threaded end 46 will be used to hold the parts together. Thus,
depending on the length of the stud 42 and height of the separator
50, the height of the airspace 18 can be adjusted. Instead of using
studs 42 welded to the upper surface of the second panels 14, bolts
can also be passed through a hole through the second panel (not
shown), adhesive can be used to hold the panels together, or other
mechanical devices can be used. Shown placed between the first,
substrate panel 12 and the second panel 14 is an optional layer of
material 58, such as fire retardant material.
[0014] One advantage of providing a construction panel as described
above is that the second panel can be formed of relatively thin and
costly materials, with the first, substrate panel 12 providing
structure support for the second panels 14, thereby allowing a
designer great flexibility in creating a desired visual and
architectural effect that could not otherwise be achieved with
panels formed of single panels.
[0015] Although embodiments of the present invention have been
described in detail hereinabove in connection with certain
exemplary embodiments, it should be understood that the invention
is not limited to the disclosed exemplary embodiments, but, on the
contrary is intended to cover various modifications and/or
equivalent arrangements included within the spirit and scope of the
present invention, as defined in the appended claims.
* * * * *