U.S. patent application number 11/494049 was filed with the patent office on 2011-03-03 for fire retardant panel apparatus and method of making and using same.
This patent application is currently assigned to Milwaukee Composites, Inc.. Invention is credited to James E. Desing, David M. Locher.
Application Number | 20110049935 11/494049 |
Document ID | / |
Family ID | 37684001 |
Filed Date | 2011-03-03 |
United States Patent
Application |
20110049935 |
Kind Code |
A1 |
Locher; David M. ; et
al. |
March 3, 2011 |
FIRE RETARDANT PANEL APPARATUS AND METHOD OF MAKING AND USING
SAME
Abstract
A flame retardant panel apparatus, and method, utilize a flame
retardant panel, having an exterior and an interior face thereof,
with the panel including a panel structure having a primary core
encapsulated within a panel frame of reinforced phenolic material,
and a layer of flame retardant material attached to the panel
structure and extending outwardly therefrom to at least partially
define an exterior face of the flame retardant panel. The flame
retardant panel is suitable for use in mass transit conveyances,
such as subway cars, high speed cars, rail cars, buses, rapid
response vehicles, marine vessels, and elevators.
Inventors: |
Locher; David M.; (Waukesha,
WI) ; Desing; James E.; (Elkhorn, WI) |
Assignee: |
Milwaukee Composites, Inc.
Oak Creek
WI
|
Family ID: |
37684001 |
Appl. No.: |
11/494049 |
Filed: |
July 27, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60703048 |
Jul 27, 2005 |
|
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|
Current U.S.
Class: |
296/193.07 ;
428/71; 428/76 |
Current CPC
Class: |
B60R 13/08 20130101;
Y10T 428/239 20150115; F24D 13/022 20130101; B61D 17/10 20130101;
Y10T 428/233 20150115; E04B 1/942 20130101; Y02B 30/00 20130101;
E04C 2/296 20130101; B66B 11/0226 20130101; E04C 2/525 20130101;
Y10T 29/49002 20150115; Y02B 30/26 20130101 |
Class at
Publication: |
296/193.07 ;
428/71; 428/76 |
International
Class: |
B62D 25/20 20060101
B62D025/20; B32B 3/00 20060101 B32B003/00; B32B 3/26 20060101
B32B003/26 |
Claims
1-6. (canceled)
7. A flame retardant panel, having an exterior face thereof adapted
for attachment to a support frame and an interior face thereof
adapted for defining a boundary of a compartment, the flame
retardant panel comprising: a panel structure including a primary
core encapsulated within a panel frame of reinforced phenolic
material, the primary core having first and second faces thereof,
and a periphery thereof, the panel frame including first and second
skins, attached to the first and second faces of the primary core,
and one or more closeouts disposed between the skins about the
periphery of the primary core, with the one or more closeouts being
attached to the periphery of the primary core and to the first and
second skins; and a layer of flame retardant material attached to
the second skin of the panel frame and extending outwardly
therefrom to at least partially define the exterior face of the
flame retardant panel, the layer of flame retardant material
comprising: a secondary core of material from the group consisting
of balsa wood, phenolic foam, and melamine foam, an additional skin
of reinforced phenolic material defining a first face thereof
attached to the secondary core and a second face thereof opposite
the secondary core, wherein the secondary core is sandwiched
between and attached to the second skin of the composite support
structure and the additional skin, and, with the additional skin
being integrally joined to the remainder of the panel frame, to
thereby fully encapsulate the secondary core within the reinforced
phenolic material comprising the panel frame, and a layer of
intumescent material having a composite structure and comprising a
coating containing an intumescent material bonded onto the second
face of the additional skin, wherein the intumescent material is
disposed in a fibrous mat; wherein, the layer of intumescent
material includes a cured epoxy resin to form a pre-cured layer of
intumescent material, and the panel further includes an adhesive
bonding the pre-cured layer of intumescent material to the second
face of the additional skin.
8. A flame retardant panel, having an exterior face thereof adapted
for attachment to a support frame and an interior face thereof
adapted for defining a boundary of a compartment, the flame
retardant panel comprising: a panel structure including a primary
core encapsulated within a panel frame of reinforced phenolic
material, the primary core having first and second faces thereof,
and a periphery thereof, the panel frame including first and second
skins, attached to the first and second faces of the primary core,
and one or more closeouts disposed between the skins about the
periphery of the primary core, with the one or more closeouts being
attached to the periphery of the primary core and to the first and
second skins; and a layer of flame retardant material attached to
the second skin of the panel frame and extending outwardly
therefrom to at least partially define the exterior face of the
flame retardant panel, the layer of flame retardant material
comprising: a secondary core of material from the group consisting
of balsa wood, phenolic foam, and melamine foam, an additional skin
of reinforced phenolic material defining a first face thereof
attached to the secondary core and a second face thereof opposite
the secondary core, wherein the secondary core is sandwiched
between and attached to the second skin of the composite support
structure and the additional skin, and, with the additional skin
being integrally joined to the remainder of the panel frame, to
thereby fully encapsulate the secondary core within the reinforced
phenolic material comprising the panel frame, and a layer of
intumescent material having a composite structure and comprising a
coating containing an intumescent material bonded onto the second
face of the additional skin, wherein the intumescent material is
disposed in a fibrous mat; wherein, the layer of intumescent
material is impregnated with phenolic resin, placed against the
second face of the additional skin of reinforced phenolic resin and
co-cured therewith.
9-14. (canceled)
15. The flame retardant panel of any one of claims 7, 8, 26, or 29,
further comprising, one or more ribs of reinforced phenolic
material connecting the first and second skins to one another and
disposed inwardly from the periphery of the primary core.
16. The flame retardant core of claim 15, wherein, the primary core
is a pre-cured reinforced core, including at least one reinforced
phenolic rib and two or more foam strips, the at least one phenolic
rib being positioned between two adjacent ones of the two or more
foam strips.
17. (canceled)
18. A flame retardant panel, having an exterior face thereof
adapted for attachment to a support frame and an interior face
thereof adapted for defining a boundary of a compartment, the flame
retardant panel comprising: a panel structure including a primary
core encapsulated within a panel frame of reinforced phenolic
material, the primary core having first and second faces thereof,
and a periphery thereof, the panel frame including first and second
skins attached to the first and second faces of the primary core,
one or more ribs of reinforced phenolic material connecting the
first and second skins to one another and disposed inwardly from
the periphery of the primary core, and one or more closeouts
disposed between the skins about the periphery of the primary core,
with the one or more closeouts being attached to the periphery of
the primary core and to the first and second skins; and a layer of
flame retardant material attached to the second skin of the panel
frame and extending outwardly therefrom to at least partially
define the exterior face of the flame retardant panel wherein: the
panel defines a longitudinal axis thereof, a transverse axis
thereof extending substantially perpendicularly to the longitudinal
axis, and a thickness thereof extending substantially orthogonally
to both the longitudinal and transverse axes of the panel, with
both the longitudinal and transverse axes lying substantially
within a plane defined by the interior face of the panel; and the
first and second skins comprise a stitched composite reinforcing
structure of fibrous material, impregnated with phenolic resin; the
reinforcing structure of the skins having first second and third
layers, the first layer being disposed adjacent the primary core
and comprised of substantially randomly directed fibers, the second
layer being disposed against the first layer and comprising
substantially longitudinally directed fibers, and the third layer
being disposed against the second layer and comprising
substantially transversely directed fibers, with the first, second,
and third layers being stitched together by stitching extending at
least partially orthogonally to the longitudinal and transverse
axes.
19. (canceled)
20. The flame retardant panel of any one of claims 7, 8, 18, 26, or
29, wherein, one or more of the one or more closeouts is
machineable to include at least one mating surface.
21. The flame retardant panel of claim 20, wherein, the mating
surface is a lap joint.
22. The flame retardant panel of claim 21, wherein, the interior
face of the panel defines a plane of the panel, the closeout
includes at least one bore therethrough extending substantially
perpendicularly to the plane of the panel.
23. The flame retardant panel of any one of claims 7, 8, 18, 26, or
29, wherein, the primary core further comprises at least one
tapping block, with the tapping block including a block of
reinforced phenolic material and a metal plate encapsulated within
the block, the tapping plate being adapted to be drilled and tapped
so as to provide the panel with a mounting area.
24. The flame retardant panel of any one of claims 7, 8, 18, 26, or
29, wherein, the primary core comprises a plastic closed cell foam
of polyisocyanurate material.
25. The flame retardant panel of any one of claims 7, 8, 18, 26, or
29, wherein, the primary core comprises a balsa wood material.
26. A flame retardant panel, having an exterior face thereof
adapted for attachment to a support frame and an interior face
thereof adapted for defining a boundary of a compartment, the flame
retardant panel comprising: a panel structure including a primary
core encapsulated within a panel frame of reinforced phenolic
material, the primary core having first and second faces thereof,
and a periphery thereof, the panel frame including first and second
skins, attached to the first and second faces of the primary core,
and one or more closeouts disposed between the skins about the
periphery of the primary core, with the one or more closeouts being
attached to the periphery of the primary core and to the first and
second skins; a layer of flame retardant material attached to the
second skin of the panel frame and extending outwardly therefrom to
at least partially define the exterior face of the flame retardant
panel; and a heating element adjacent the interior face of the
panel.
27. The flame retardant panel of claim 26, wherein, the heating
element is embedded into the first skin of the panel, and
integrally joined thereto by the phenolic material.
28. (canceled)
29. A flame retardant panel, having an exterior face thereof
adapted for attachment to a support frame and an interior face
thereof adapted for defining a boundary of a compartment, the flame
retardant panel comprising: a panel structure including a primary
core encapsulated within a panel frame of reinforced phenolic
material, the primary core having first and second faces thereof,
and a periphery thereof, the panel frame including first and second
skins, attached to the first and second faces of the primary core,
and one or more closeouts disposed between the skins about the
periphery of the primary core, with the one or more closeouts being
attached to the periphery of the primary core and to the first and
second skins; and a layer of flame retardant material attached to
the second skin of the panel frame and extending outwardly
therefrom to at least partially define the exterior face of the
flame retardant panel, wherein the panel defines a longitudinal
axis thereof, a transverse axis thereof extending substantially
perpendicularly to the longitudinal axis, and a thickness thereof
extending substantially orthogonally to both the longitudinal and
transverse axes of the panel, with both the longitudinal and
transverse axes lying substantially within a plane defined by the
interior face of the panel, wherein the thickness of the panel
varies and includes at least a first and a second thickness
thereof, within the periphery of the primary core, and wherein the
layer of flame retardant material attached to the second skin of
the panel frame and extending outwardly therefrom to at least
partially define the exterior face of the panel extends across the
entirety of the exterior face of the panel, throughout both the
first and second thicknesses of the panel.
30. The flame retardant panel of claim 29, wherein, the layer of
flame retardant material attached to the second skin of the panel
frame and extending outwardly therefrom to at least partially
define the exterior face of the panel extends only partially across
the entirety of the exterior face of the panel, throughout one but
not both of the first and second thicknesses of the panel.
31. A flame retardant panel, having an exterior face thereof
adapted for attachment to a support frame and an interior face
thereof adapted for defining a boundary of a compartment, the flame
retardant panel comprising: a panel structure including a primary
core encapsulated within a panel frame of reinforced phenolic
material, the primary core having first and second faces thereof,
and a periphery thereof, the panel frame including first and second
skins, attached to the first and second faces of the primary core,
and one or more closeouts disposed between the skins about the
periphery of the primary core, with the one or more closeouts being
attached to the periphery of the primary core and to the first and
second skins; and a layer of flame retardant material attached to
the second skin of the panel frame and extending outwardly
therefrom to at least partially define the exterior face of the
flame retardant panel, wherein the panel defines a longitudinal
axis thereof, a transverse axis thereof extending substantially
perpendicularly to the longitudinal axis, and a thickness thereof
extending substantially orthogonally to both the longitudinal and
transverse axes of the panel, with both the longitudinal and
transverse axes lying substantially within a plane defined by the
interior face of the panel, wherein the thickness of the panel
varies and includes at least a first and a second thickness
thereof, within the periphery of the primary core, and wherein the
layer of flame retardant material attached to the second skin of
the panel frame and extending outwardly therefrom to at least
partially define the exterior face of the panel comprises: a first
flame retardant structure in areas of the panel having the first
thickness; and a second flame retardant structure in areas of the
panel having the second thickness.
32. The flame retardant panel of claim 31, wherein the first flame
retardant structure of the layer of flame retardant material
comprises, a secondary core of material from the group comprising
balsa wood, phenolic foam, and melamine foam, and an additional
skin of reinforced phenolic material, with the secondary core being
sandwiched between and attached to the second skin of the composite
support structure and the additional skin, and, with the additional
skin being integrally joined to the remainder of the panel frame,
to thereby fully encapsulate the secondary core within the
reinforced phenolic material comprising the panel frame.
33. The flame retardant panel of claim 32, wherein, the second
flame retardant structure of layer of flame retardant material
comprises a layer of intumescent material attached to the second
face of the second skin.
34. The flame retardant panel of claim 33, wherein, the layer of
intumescent material is bonded onto the second face of the second
skin.
35. The flame retardant panel of claim 34, wherein, the layer of
intumescent material comprises a coating containing an intumescent
material.
36. The flame retardant panel of claim 34, wherein, the layer of
intumescent coating is a composite structure including an
intumescent material disposed in a fibrous mat.
37. The flame retardant panel of claim 36, wherein, the layer of
intumescent material includes a cured epoxy resin to form a
pre-cured layer of intumescent material, and the panel further
includes an adhesive bonding the pre-cured layer of intumescent
material to the second face of the additional skin.
38. The flame retardant panel of claim 36, wherein, the layer of
intumescent material is impregnated with phenolic resin, placed
against the second face of the additional layer of reinforced
phenolic resin and co-cured therewith.
39. A flame retardant panel, having an exterior face thereof
adapted for attachment to a support frame and an interior face
thereof adapted for defining a boundary of a compartment, the flame
retardant panel comprising: a panel structure including a primary
core encapsulated within a panel frame of reinforced phenolic
material, the primary core having first and second faces thereof,
and a periphery thereof, the panel frame including first and second
skins, attached to the first and second faces of the primary core,
and one or more closeouts disposed between the skins about the
periphery of the primary core, with the one or more closeouts being
attached to the periphery of the primary core and to the first and
second skins; and a layer of flame retardant material attached to
the second skin of the panel frame and extending outwardly
therefrom to at least partially define the exterior face of the
flame retardant panel; and a conduit embedded within the panel and
having first and second openings into the conduit through at least
one of the interior or exterior faces or the perimeter of the
panel.
40. (canceled)
41. The flame retardant panel apparatus of any one of claims 44 or
46, wherein, the layer of flame retardant material comprises, a
secondary core of material from the group comprising balsa wood,
phenolic foam, and melamine foam, and an additional skin of
reinforced phenolic material, with the secondary core being
sandwiched between and attached to the second skin of the composite
support structure and the additional skin, and, with the additional
skin being integrally joined to the remainder of the panel frame,
to thereby folly encapsulate the secondary core within the
reinforced phenolic material comprising the panel frame.
42-43. (canceled)
44. A flame retardant panel apparatus, having multiple
interconnected panels each including an exterior face thereof
adapted for attachment to a support frame and an interior face
thereof adapted for defining a boundary of a compartment, with at
least one of the panels of the flame retardant panel apparatus
being a flame retardant panel comprising: a panel structure
including a primary core encapsulated within a panel frame of
reinforced phenolic material, the primary core having first and
second faces thereof, and a periphery thereof, the panel frame
including first and second skins, attached to the first and second
faces of the primary core, and one or more closeouts disposed
between the skins about the periphery of the primary core, with the
one or more closeouts being attached to the periphery of the
primary core and to the first and second skins; and a layer of
flame retardant material attached to the second skin of the panel
frame and extending outwardly therefrom to at least partially
define the exterior face of the panel, wherein the flame retardant
panel defines a longitudinal axis thereof, a transverse axis
thereof extending substantially perpendicularly to the longitudinal
axis, and a thickness thereof extending substantially orthogonally
to both the longitudinal and transverse axes of the panel, with
both the longitudinal and transverse axes lying substantially
within a plane defined by the interior face of the panel, wherein
the thickness of the fire retardant panel varies and includes at
least a first and a second thickness thereof, within the periphery
of the primary core, and wherein, the layer of flame retardant
material attached to the second skin of the panel frame and
extending outwardly therefrom to at least partially define the
exterior face of the panel extends across the entirety of the
exterior face of the panel, throughout both the first and second
thicknesses of the panel.
45. The flame retardant panel apparatus of claim 46, wherein, the
layer of flame retardant material attached to the second skin of
the panel frame and extending outwardly therefrom to at least
partially define the exterior face of the panel extends only
partially across the entirety of the exterior face of the panel,
throughout one, but not both of, the first and second thicknesses
of the panel.
46. A flame retardant panel apparatus, having multiple
interconnected panels each including an exterior face thereof
adapted for attachment to a support frame and an interior face
thereof adapted for defining a boundary of a compartment, with at
least one of the panels of the flame retardant panel apparatus
being a flame retardant panel comprising: a panel structure
including a primary core encapsulated within a panel frame of
reinforced phenolic material, the primary core having first and
second faces thereof, and a periphery thereof, the panel frame
including first and second skins, attached to the first and second
faces of the primary core, and one or more closeouts disposed
between the skins about the periphery of the primary core, with the
one or more closeouts being attached to the periphery of the
primary core and to the first and second skins; and a layer of
flame retardant material attached to the second skin of the panel
frame and extending outwardly therefrom to at least partially
define the exterior face of the panel, wherein the flame retardant
panel defines a longitudinal axis thereof, a transverse axis
thereof extending substantially perpendicularly to the longitudinal
axis, and a thickness thereof extending substantially orthogonally
to both the longitudinal and transverse axes of the panel, with
both the longitudinal and transverse axes lying substantially
within a plane defined by the interior face of the panel, wherein
the thickness of the fire retardant panel varies and includes at
least a first and a second thickness thereof, within the periphery
of the primary core, and the flame retardant panel further
comprises: a first flame retardant structure in areas of the panel
having the first thickness; and a second flame retardant structure
in areas of the panel having the second thickness.
47. The flame retardant panel apparatus of any one of claims 44 or
46, wherein, the panel apparatus comprises a flooring apparatus of
a conveyance.
48. The flame retardant panel apparatus of claim 47, wherein, the
conveyance is an elevator including a floor support structure
adapted for attachment thereto of the flooring apparatus.
49. The flame retardant panel apparatus of claim 47, wherein, the
conveyance is a vehicle or vessel including a floor support
structure adapted for attachment thereto of the flooring
apparatus.
50. The flame retardant panel apparatus of claim 49, wherein, the
vehicle or vessel is a mass transit vehicle or vessel.
51-66. (canceled)
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This patent application claims the benefit of U.S.
Provisional Patent Application No. 60/703,048, filed Jul. 27, 2005,
the disclosure and teachings of which are incorporated herein, by
reference, in their entirety.
FIELD OF THE INVENTION
[0002] This invention relates generally to fire retardant panels,
and more particularly to fire retardant panels suitable for use in
mass transit conveyances, such as subway cars, high speed cars,
rail cars, buses, rapid response vehicles, marine vessels, or
elevator cars.
BACKGROUND OF THE INVENTION
[0003] Public conveyances, such as rail cars, buses, elevators, and
the like, are typically subject to government regulations requiring
that a passenger compartment of the conveyance be at least
partially constructed from fire retardant panels, which provide
protection for occupants of the compartment in the event that a
fire should occur outside or within the passenger compartment.
[0004] For example, in the past, passenger rail cars and buses have
sometimes utilized a flooring system in which floor panels,
approximately three-quarters of an inch thick, are mounted to the
top side of a floor-supporting underframe. Typically the floor
panels have been attached to the underframe by various methods,
including adhesive bonding, or fastening with screws or other
fasteners. The underframe has typically been deep enough to allow a
layer of insulation material (usually glass wool, fiberglass, or
rock wool), to be laid upon the top surface of a series of thin
steel sheets that are then welded to the bottom side of the
underframe, to form an underpan assembly. The underframe is
sometimes configured to be deep enough that there is an air gap
provided between the underside of the floor panel and the
insulation material on the top side of the steel underpan. The air
gap serves as an insulation zone for heat transfer, in the event of
a fire beneath the transit vehicle. Typically, in North America,
such a floor structure is required to pass a fire endurance test
for passenger fire safety, in which a completed flooring system is
mounted over a pit in which a gas burner is located to simulate a
fire beneath the vehicle. During the fire test, weights are placed
on the top surface of the floor panels, to simulate a typical live
floor loading resulting from carrying passengers.
[0005] In one common form of a floor panel, used in prior flooring
systems for mass transit vehicles, a plywood sheet is sandwiched
between, and bonded to, the interior surfaces of two stainless
steel or aluminum sheets. This construction results in floor panels
that are heavier than is desirable. Also, past experience has shown
that, during operation of the mass transit vehicle, the plywood
core sometimes is exposed to water, which causes the stainless
steel or aluminum sheets to delaminate and the plywood panel to
rot.
[0006] U.S. Pat. No. 6,824,851, which is assigned to the Assignee
of the present invention, and is hereby incorporated in its
entirety herein by reference, discloses an approximately
three-quarter inch thick phenolic composite flooring system for
mass transit vehicles, which provides significant improvement over
flooring systems utilizing floor panels having stainless steel or
aluminum sheets bonded to the faces of a plywood panel. By virtue
of its construction, the phenolic composite flooring system
disclosed in U.S. Pat. No. 6,824,851 is considerably lighter in
weight than flooring systems utilizing plywood panels clad with
stainless steel or aluminum sheets. Also, the flooring system of
the '851 patent provides greater ability, than flooring systems
using floor panels having a plywood sheet clad with stainless steel
skins, to withstand harsh environmental conditions, such as
exposure to water or moisture.
[0007] Although use of a phenolic composite flooring system,
according to U.S. Pat. No. 6,824,851, in a traditional mass transit
vehicle constructions, having an insulation material laid on the
top surface of thin steel sheets welded to the bottom of a steel
underframe to form an underpan assembly, have been shown to provide
significant advantages over similar systems utilizing metal clad
plywood floor panels, further improvement is desirable.
[0008] It is desirable to eliminate the insulation and heavy steel
underpan, to reduce weight and complexity of the transit vehicle,
and to eliminate the cost of the insulation, the steel underpan,
and costs incurred in installing the insulation and underpan onto
the underframe of the vehicle, while still providing sufficient
flame retardant capability to meet governmental regulations.
[0009] Past experience has also shown that use of the air gap and
steel underpan in previous mass transit vehicles created a cavity
between the underpan and the floor panels which "drummed" during
use of the mass transit vehicle. Elimination of the underpan and
air gap would also eliminate the cavity, and potentially lead to a
quieter passenger cab environment.
[0010] It has also been observed that previous, conventional
underpan and underframe assemblies, would, from time-to-time, trap
water between the bottom of the floor panel and the top side of the
underpan. In some instances, large amounts of standing water would
be trapped within the cavity between the underpan and the floor
panels. As noted above, this standing water sometimes damage the
floor panels, and could amount to significant dead weight which had
to be carried by the mass transit vehicle.
[0011] It is desirable, therefore, to provide an improved fire
retardant panel apparatus, and a method of making and using such an
improved fire retardant panel apparatus, in a form which addresses
one or more of the disadvantages of prior flooring systems for mass
transit vehicles. It is further desirable to produce a fire
retardant panel for use in other conveyances such as elevators and
marine vessels. It is further desirable to provide an improved fire
retardant panel, and panel apparatus, for use in defining one or
more of the floor, ceiling, and/or walls of a conveyance for
transporting passengers or other cargo.
BRIEF SUMMARY OF THE INVENTION
[0012] The invention provides an improved flame retardant panel
apparatus, and method of making and using such an improved fire
retardant panel apparatus, through use of a flame retardant panel,
having an exterior and an interior face thereof, with the panel
including a panel structure having a primary core encapsulated
within a panel frame of reinforced phenolic material, and a layer
of flame retardant material attached to the panel structure and
extending outwardly therefrom to at least partially define an
exterior face of the flame retardant panel.
[0013] Through use of a flame retardant panel, according to the
invention, in a mass transit conveyance, such as a rail car or a
bus, for example, the underpan and layer of insulation beneath the
floor panel, of prior mass transit flooring systems, can be
eliminated, while still providing an enhanced flame retardant
capability which meets or exceeds applicable government standards.
Through use of a flame retardant panel, according to the invention,
weight and complexity of a mass transit flooring system are
significantly reduced. In addition, a flame retardant panel,
according to the invention, provides improved thermal insulation
capabilities, and resistance to sound transmission, as compared to
prior flame retardant panel constructions. Flame retardant panels,
according to the invention, are also inherently more capable of
withstanding exposure to water, and provide an improved moisture
barrier, as compared to the metal clad plywood floor panels
utilized in prior mass transit vehicles.
[0014] In one form of the invention, a flame retardant panel,
according to the invention, has an exterior face thereof adapted
for attachment to a support frame and an interior face thereof
adapted for defining a boundary of a compartment. The flame
retardant panel includes a panel structure and a layer of flame
retardant material attached to the panel structure. The panel
structure includes a primary core encapsulated within a panel frame
of reinforced phenolic material. The primary core has first and
second faces thereof and a periphery thereof. The panel structure
further includes a panel frame including first and second skins,
attached to the first and second faces of the primary core, and one
or more closeouts disposed between the skins about the periphery of
the core, with the one or more closeouts being attached to the
periphery of the primary core and to the first and second skins.
The layer of flame retardant material is attached to the second
skin of the panel frame, and extends outwardly therefrom to at
least partially define the exterior face of the flame retardant
panel.
[0015] In some forms of the invention, the layer of flame retardant
material includes a secondary core of material from the group
consisting of balsa wood, phenolic foam, and melamine foam, and an
additional skin of reinforced phenolic material. The secondary core
is sandwiched between, and attached to, the second skin of the
composite support structure and the additional skin. The additional
skin is integrally joined to the remainder of the panel frame, to
thereby fully encapsulate the secondary core within the reinforced
phenolic material from which the panel frame is constructed.
[0016] In some forms of the invention, the layer of flame retardant
material includes a layer of intumescent material attached to the
second skin. The layer of intumescent material may be bonded onto
the second skin. The layer of intumescent material may be a coating
containing a intumescent material, which is sprayed, or otherwise
applied onto the second skin. The layer of intumescent coating may
also take the form of a composite structure, including an
intumescent material disposed in a fibrous mat. In some forms of
the invention, the layer of intumescent material includes a cured
epoxy resin to form a pre-cured layer of intumescent material which
is adhesively bonded to the second skin, utilizing an epoxy or
other suitable type of adhesive. In some forms of the invention,
the layer of intumescent material is impregnated with phenolic
resin and placed against the second skin of reinforced phenolic
resin, while the second skin is in an uncured state. The
impregnated layer of intumescent material and the second skin are
then co-cured. Co-curing of the impregnated intumescent material
with the second skin, may be carried out contemporaneously with
curing of the remainder of the panel frame of reinforced phenolic
material.
[0017] In some forms of the invention, the primary core of the
panel structure may include a plastic closed cell foam of
polyisocyanurate material. The primary core may also be formed from
other appropriate materials such as balsa wood.
[0018] In some forms of the invention, the panel structure may
include one or more ribs of reinforced phenolic material connecting
the first and second skins to one another, and disposed inwardly
from the periphery of the primary core. The primary core may be a
pre-cured reinforced core, including at least one reinforced
phenolic rib and two or more foam strips, with the at least one
phenolic rib being positioned between two adjacent ones of the two
or more foam strips. Alternatively, the primary core may include a
plurality of groupings, each formed from a plurality of plastic
foam strips helically wound together in a side-by-side
relationship, by rovings of fibrous material. The groupings may be
disposed in a side-by-side relationship with one another, and
joined together by first and second adhesive scrims applied to
first and second faces of the primary core, such that facing and
faying portions of the fibrous rovings of adjacent groupings form
reinforcements for the reinforced phenolic ribs.
[0019] A fire retardant panel, according to the invention, may
define a longitudinal axis thereof, a transverse axis thereof
extending substantially perpendicularly to the longitudinal axis,
and a thickness thereof extending substantially orthogonally to
both the longitudinal and transverse axes of the panel, with both
the longitudinal and transverse axes lying substantially within a
plane defined by the interior face of the panel. The first and
second skins may take the form of a stitched composite reinforcing
structure of fibrous material, impregnated with phenolic resin. The
reinforcing structure of the skins may have first, second and third
layers, with the first layer being disposed adjacent the primary
core and comprised of substantially randomly directed fibers, the
second layer being disposed against the first layer and comprising
substantially longitudinally directed fibers, and the third layer
being disposed against the second layer and comprising
substantially transversely directed fibers, with the first, second,
and third layers being stitched together by stitching extending at
least partially orthogonally to the longitudinal and transverse
axes.
[0020] In forms of the invention having an additional skin of
reinforced phenolic material, the additional skin may also be
constructed as described in the preceding paragraph, with the first
layer of the reinforcing structure of the additional skin being
attached to the secondary core.
[0021] A flame retardant panel, according to the invention, may
also include a surfacing veil disposed against the third layer of
the reinforcing structure of one of the first, second, or
additional skins of reinforced phenolic material.
[0022] One or more of the one or more closeouts, in a flame
retardant panel, according to the invention, may be machineable to
include at least one mating surface. The mating surface may be a
lap joint.
[0023] Where the interior face, of a flame retardant panel,
according to the invention, defines a plane of the panel, a
closeout, according to the invention, may include at least one bore
therethrough extending substantially perpendicularly to the plane
of the panel. The primary core, in a flame retardant panel,
according to the invention, may include at least one tapping block,
with the tapping block including a block of reinforced phenolic
material and a metal plate encapsulated within the block. The
tapping plate may be adapted to be drilled and tapped, so as to
provide the panel with a mounting area.
[0024] A flame retardant panel, according to the invention, may
include a heating element adjacent to the interior face of the
panel. The heating element may be embedded into the first skin of
the panel, and integrally joined thereto by the phenolic material.
The heating element may also be adhesively bonded onto the first
skin of the panel, using an appropriate adhesive. The heating
element may be encapsulated within a sheath of urethane material,
and be adhesively bonded to the first skin with an epoxy adhesive,
or another appropriate adhesive.
[0025] A flame retardant panel, in accordance with the invention,
may include a conduit embedded within the panel and having first
and second openings into the conduit through at least one of the
interior and/or exterior faces of the panel or the perimeter such
that the conduit continues from panel to panel.
[0026] The invention may also take the form of a flame retardant
panel apparatus, having multiple interconnected panels, each
including an exterior face thereof adapted for attachment to a
support frame and an interior face thereof adapted for defining a
boundary of a compartment, with at least one of the panels of the
flame retardant panel apparatus being a flame retardant panel
according to the invention.
[0027] A flame retardant panel apparatus, in accordance with the
invention, may take the form of a flooring apparatus for a
conveyance. The conveyance may be an elevator, including a floor
support structure adapted for attachment thereto of the flooring
apparatus according to the invention. The conveyance may be a
vehicle or a vessel including a floor support structure adapted for
attachment thereto of a flooring apparatus according to the
invention. The vehicle or vessel may be a mass transit vehicle or
vessel.
[0028] The invention may also take the form of a method for
constructing and/or using a flame retardant panel, or a flame
retardant panel apparatus, in accordance with the invention.
[0029] In one form of the invention, a method is provided for
constructing a flame retardant panel, having an exterior face
thereof adapted for attachment to a support frame and an interior
face thereof adapted for defining a boundary of a compartment. The
method includes forming a panel structure, and attaching a layer of
flame retardant material to the panel structure. The panel
structure is formed by encapsulating a primary core within a panel
frame of reinforced phenolic material, in such a manner that the
primary core has first and second faces thereof, and a periphery
thereof, and such that the panel frame includes first and second
skins attached to the first and second faces of the primary core
and one or more closeouts disposed between the skins about the
periphery of the primary core, with the one or more closeouts being
attached to the periphery of the primary core and to the first and
second skins. The layer of flame retardant material is attached to
the second skin of the panel frame and extends outwardly therefrom,
such that the layer of flame retardant material at least partially
defines the exterior face of the panel.
[0030] A method, according to the invention, may include forming
the layer of flame retardant material from a secondary core, and an
additional skin of reinforced phenolic material, where the
secondary core is formed from a material selected from the group
consisting of balsa wood, phenolic foam, and melamine foam. The
method includes attaching the secondary core between the second
skin of the panel structure and the additional skin. A method,
according to the invention, may further include integrally joining
the additional skin to the remainder of the panel frame, of the
panel structure, to thereby fully encapsulate the secondary core
within the reinforced phenolic material of the panel frame.
[0031] Alternatively, a method for constructing a flame retardant
panel, in accordance with the invention, may include forming the
layer of flame retardant material by attaching an intumescent
material to the second skin of the panel structure.
[0032] In some forms of the invention, the thickness of a fire
retardant panel, according to the invention, may vary and include
at least a first and a second thickness thereof, within the
periphery of the primary core. The layer of flame retardant
material attached to the second skin of the panel frame and
extending outwardly therefrom to at least partially define the
exterior surface of the panel may extend across the entirety of the
exterior face of the panel, throughout both the first and second
thicknesses of the panel. Alternatively, the layer of flame
retardant material attached to the second skin of the panel frame
and extend outwardly therefrom to at least partially define the
exterior surface of the panel may extend only partially across the
entirety of the exterior face of the panel, throughout one, but not
both of the first and second thicknesses of the panel. In some
forms of the invention, a first flame retardant structure may be
utilized in areas of the panel having the first thickness, and a
second flame retardant structure may be utilized in areas of the
panel having the second thickness. For example, a flame retardant
structure including a secondary core of flame retardant material
may be utilized in areas of the panel having the first thickness,
and a second flame retardant structure including an intumescent
material may be utilized in areas of the panel having the second
thickness.
[0033] Similarly, even where the panel has a substantially uniform
thickness, the layer of flame retardant material may include first
and second sections thereof having different flame retardant
structures. For example, the first section of the layer of flame
retardant material may be formed from a secondary core and an
additional skin, according to the invention, with the second
section of the layer of flame retardant material being formed from
an intumescent material attached to the second skin of the panel
structure in the second section of the flame retardant layer.
[0034] Other aspects, objects and advantages of the invention will
be apparent from the following detailed description and
accompanying drawings of exemplary embodiments of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] The accompanying drawings incorporated in and forming a part
of the specification illustrate several aspects of the present
invention and, together with the description, serve to explain the
principles of the invention. In the drawings:
[0036] FIG. 1 is a perspective illustration of a first exemplary
embodiment of a fire retardant panel, in accordance with the
invention;
[0037] FIG. 2 is an exploded perspective illustration, showing the
internal components and construction of the exemplary embodiment of
the fire retardant panel shown in FIG. 1;
[0038] FIG. 3 is a partial cross-sectional illustration of an
exemplary embodiment of a fire retardant panel, according to the
invention, which includes a fire retardant layer having a secondary
core of fire retardant material;
[0039] FIG. 4 is a partial cross-sectional view of an exemplary
embodiment of the invention having a layer of intumescent material
at least partially defining an exterior face of a flame retardant
panel, according to the invention;
[0040] FIG. 5 is a perspective illustration of an alternate
embodiment of a primary core of the exemplary embodiment of the
fire retardant panel shown in FIG. 1;
[0041] FIGS. 6A-6D are partial cross-sectional illustrations of an
edge of a flame retardant panel, according to the invention, taken
along line 6-6 in FIG. 8B, illustrating construction details of
several alternate embodiments of the invention;
[0042] FIGS. 7A-7E are perspective, plan, and elevation views of a
fire retardant panel apparatus, according to the invention, in the
form of a flooring apparatus for a mass transit rail car;
[0043] FIGS. 8A-8C are respectively top, bottom, and end views of
an exemplary embodiment of a fire retardant floor panel, according
to the invention, having sections of greater and lesser thickness
to facilitate installation of the floor panel onto a support
structure;
[0044] FIGS. 9A-9D are alternate partial cross-sectional views
taken along line 9-9 in FIG. 8B, illustrating construction details
of alternate embodiments of fire retardant panels, according to the
invention, having areas of greater and lesser thickness located
inwardly from the edges of the panel; and
[0045] FIG. 10 illustrates alternate embodiments of the exemplary
embodiment of the fire retardant panel shown in FIG. 1, wherein the
alternate embodiments include a heating element attached to an
interior surface of the panel, and a conduit disposed within the
panel for passage of wires, or the like through the panel.
[0046] While the invention will be described in connection with
certain preferred embodiments, there is no intent to limit it to
those embodiments. On the contrary, the intent is to cover all
alternatives, modifications and equivalents as included within the
spirit and scope of the invention as defined by the appended
claims.
DETAILED DESCRIPTION OF THE INVENTION
[0047] FIGS. 1 and 2 illustrate a first exemplary embodiment of a
flame retardant panel 100, according to the invention, with FIG. 1
showing the flame retardant panel in a completed state, ready for
attachment to a support frame, and FIG. 2 illustrating various
components of the flame retardant panel 100 in an exploded
perspective fashion.
[0048] As shown in FIGS. 1 and 2, the first exemplary embodiment of
a flame retardant panel 100, according to the invention, has an
exterior face 102 thereof, adapted for attachment to a support
frame (not shown), an interior face 104 thereof, adapted for
defining a boundary of a compartment and a perimeter 105 thereof
extending around the panel 100 between the interior and exterior
faces 104, 106 of the panel 100. The flame retardant panel 100
includes a panel structure 106 including a primary core 108 having
first and second faces 110, 112 thereof and a periphery 114
thereof. In the first exemplary embodiment of the flame retardant
panel, as illustrated in FIG. 2, the primary core 108 has
essentially a planar shape, with the first and second faces 110,
112 forming spaced parallel planes, and the periphery 114 being
substantially rectangular in shape. In other embodiments of the
invention, flame retardant panels, and components thereof may have
shapes differing considerably from those illustrated in the
exemplary embodiment of the flame retardant panel 100 shown in
FIGS. 1 and 2.
[0049] In the panel structure 106 of the exemplary embodiment 100,
the primary core 108 is encapsulated within a panel frame of
reinforced phenolic material, (illustrated generally by reference
numeral 116 in FIG. 2), formed by the combination of first and
second skins 118, 120, attached to the first and second faces 110,
112 of the primary core 108, and four closeouts 122, 124, 126, 128,
disposed between the skins 118, 120 about the periphery 114 of the
primary core 108. The four closeouts 122, 124, 126, 128 are
attached to the periphery 114 of the primary core 108, and to both
the first and second skins 118, 120.
[0050] A layer of flame retardant material 130 is attached to the
second skin 120 of the panel frame 116, and extends outwardly from
the second skin 120, to at least partially define the exterior face
102 of the flame retardant panel 100. The flame retardant layer 130
is illustrated as a solid slab in FIG. 2, but as will be understood
from the description below, in various embodiments of the invention
the layer of flame retardant material 130 may take a variety of
forms and include multiple elements thereof.
[0051] As shown in FIG. 3, for example, the layer of flame
retardant material 130 may include a secondary core 132 formed from
material selected from the group consisting of balsa wood, phenolic
foam, and melamine foam. In the embodiment shown in FIG. 3, the
layer of flame retardant material further includes an additional
skin 134 of reinforced phenolic material, with the secondary core
130 being sandwiched between and attached to the second skin 120 of
the composite support structure 106 and the additional skin 134.
The additional skin 134 is integrally joined to the remainder of
the panel frame 116, by the closeouts 122, 124, 126, 128, to
thereby fully encapsulate the secondary core 132 within the
reinforced phenolic material comprising the panel frame 116.
[0052] The choice of materials for the secondary core 132 will be
dependent upon a variety of factors, unique to a particular
embodiment and application of the present invention. Such factors
as the thickness of the primary core 108, and the secondary core
132 are relevant in making the choice of materials for both the
primary and secondary cores 108, 132. In general, it is
contemplated that the primary core 108 of the present invention
will have a substantially greater thickness than the core of the
applicant's '851 floor panel. For example, it is contemplated that,
in practicing the present invention, it may be desirable to have
the primary core have a thickness in the range of two inches, or
more, to enhance thermal resistance, acoustic resistance, and
structural strength of the fire retardant panel 100. It is noted,
however, that the invention may be practiced in fire retardant
panels 100, having an overall thickness T of 3/4 of an inch, for
example.
[0053] Specifically, with regard to factors considered in selecting
a material for a secondary core 132, according to the invention, it
is generally contemplated that a preferred thickness for the
secondary core would be in the range of 1/4 to 3/4 inches, with a
nominal 1/2 inch thickness being generally acceptable. The
invention may be practiced, however, with secondary cores 132
having substantially greater or lesser thicknesses than these. It
is also contemplated, that, in some embodiments of the invention,
the secondary core 132 may have a thickness which is substantially
greater than the thickness of the primary core 108. For example,
where it is desirable to have a floor panel of a mass transit
conveyance have a thickness of 3/4 of an inch above a floor support
frame, to match the thickness of prior floor panels, the panel
structure 106 of a flame retardant floor panel, according to the
invention, may have an overall thickness, across the first and
second skins and primary core 118, 120, 108, of 3/4 of an inch,
with the secondary core 132 and additional skin 134 extending a
larger distance, such as two to three inches, for example, below
the second skin 120 of the panel structure 106.
[0054] In general, balsa wood will have the lowest cost of any of
the materials listed above, for use as a secondary core 132,
according to the invention. Phenolic foam will typically cost
somewhat more than balsa wood, but provides enhanced thermal
insulation, as compared to the same thickness of balsa wood.
Melamine foam, also typically costs more than balsa wood, but
provides superior acoustic insulation, as compared to balsa wood.
Generally therefore, where lowest cost is a primary objective, it
is contemplated that a secondary core 132 of balsa wood will be
preferred, in practicing the invention. Where enhanced thermal
performance is desired, a secondary core of phenolic foam may be
preferable. Where enhanced acoustic damping performance is
required, a secondary core of melamine foam may be the preferred
choice.
[0055] As an alternative to having the additional skin 134
integrally joined to the remainder of the panel frame 116 by the
closeouts 122, 124, 126, 128, secondary closeouts of reinforced
phenolic material (not shown) may be positioned about all, or a
portion of the periphery of the secondary core 132, in alternate
embodiments of the invention. Alternatively, the additional skin
134 may be configured to wrap around the edges of the secondary
core 132, for attachment to the remainder of the panel frame 116,
in a manner which fully encapsulates the secondary core 132 within
the reinforced phenolic material comprising the panel frame 116 and
the additional skin 134.
[0056] As indicated by a dashed line, in FIG. 3, in alternate
embodiments of the invention, the layer of flame retardant material
130 may further include a layer of intumescent material 136
attached to a second face 138 of the additional skin 134. The layer
of intumescent material 136 may take a variety of forms, bonded
onto the second face 138 of the additional skin 134. For example,
the layer of intumescent material 136 may take the form of a
coating containing an intumescent material which is sprayed onto,
or otherwise applied to the second face 138 of the additional skin
134. Alternatively, the layer of intumescent material 136 may be a
composite structure including an intumescent material disposed in a
fibrous mat. Such materials are disclosed in U.S. Pat. No.
5,523,059, for example. One such material, having an unexpanded
exfoliating intumescent material disposed in a fiber mat is sold
under the trade name, Technofire.RTM., by Technical Fibre Products
of Newburgh, N.Y., US. In some forms of the invention, the fibrous
mat having the intumescent material disposed therein is impregnated
with a resin, such as an epoxy, to form a pre-cured layer of
intumescent material, which is then bonded to the second face 138
of the additional skin 136 with an adhesive, such as an epoxy. In
other embodiments, the fibrous mat containing the intumescent
material is impregnated with phenolic resin and placed against the
second face 134 of the additional skin, while the additional skin
is in an uncured state, and the layer of intumescent material 136
and the additional skin 134 are co-cured.
[0057] The choice of attaching the fibrous mat containing
intumescent material 136 to the additional skin 134 by co-curing,
or alternatively by attaching a pre-cured layer 136 of intumescent
material to the additional skin 134 may be made as a function of
how rapidly it is desired that the intumescent material be
activated. Specifically, phenolic resins have higher temperature
capabilities then epoxy resins, and will slow the rate at which the
intumescent material begins to expand out of the layer of
intumescent material 136.
[0058] Where the layer of intumescent material 136 is provided by
applying a coating to the second surface 138 of the additional skin
134, either ceramic based or non-ceramic based intumescent coatings
may be used in practicing the invention. Suitable intumescent
coatings, for use in practicing the invention, are available from
Micro Phase Coatings, Inc. of Garner, N.C., US. or Avtec Industries
of Hudson, Mass., US.
[0059] FIG. 4 illustrates a variation of the first exemplary
embodiment of the flame retardant panel 100, in which the layer of
flame retardant material 130 is formed by a layer 136 of
intumescent material which is attached directly to the second skin
120 of the panel structure 106. The layer of intumescent material
136 utilized as shown in FIG. 4, may take any of the forms and be
attached by any of the methods described above in relation to the
embodiment shown in FIG. 3.
[0060] As shown in FIGS. 2-4, the first exemplary embodiment of the
flame retardant panel 100 also includes one or more ribs 140 of
reinforced phenolic material connecting the first and second skins
118, 120 to one another. The ribs 140 are disposed inwardly from
the periphery 114 of the primary core 108.
[0061] In the exemplary embodiment 100 shown in FIG. 2, the primary
core 108 is a pre-cured reinforced core, including a plurality of
the reinforced phenolic ribs 140 alternated with a plurality of
foam strips 142, with the phenolic ribs 140 being generally
positioned between two adjacent ones of the foam strips 142. The
construction of such a pre-cured reinforced core is disclosed in
detail in commonly assigned U.S. Pat. No. 6,824,851 B1, which has
hereinabove been incorporated into the disclosure of the present
invention by reference.
[0062] In manufacturing a fire retardant panel, according to the
present invention, utilizing the pre-cured reinforced core 108, the
various components of the fire retardant panel 100 are stacked in a
platen press, substantially in the manner indicated in FIG. 2, with
uncured phenolic resin being applied between the various components
where it is desired to have the components adhere to one another,
and the stacked uncured structure is subjected to pressure and heat
to cure the phenolic material to thereby integrally bond the
components of the fire retardant panel 100 to one another.
[0063] In practicing the present invention, it is not required to
use a pre-cured core, of the type disclosed in the common
assignee's U.S. Pat. No. 6,824,851 B1. In an alternate embodiment
of a primary core 144, in a fire retardant panel, according to the
invention, illustrated in FIG. 5, the primary core 144 comprises
four groupings 146, each formed from two plastic foam strips 147
which are bond together in a side-by-side relationship by an
overwind of helically directed rovings 148, 150 of fibrous
material. The rovings 148, 150 are more-or-less oppositely
directed, and placed in alternating layers, such that the plastic
foam strips 147 in each grouping are relatively tightly bound
together by the rovings 148, 150. The groupings 146 are disposed in
a side-by-side relationship with one another, and joined by first
and second scrims 152 adhesively bonded respectively to the first
and second faces 110, 112 of the primary core 144, in such a manner
that faying portions 153 of the fibrous rovings 148, 150 form dry,
un-impregnated reinforcements for the reinforced phenolic ribs
140.
[0064] When constructing the flame retardant panel 100, utilizing
the alternate primary core 144, the various components of the flame
retardant panel 100 are stacked into a platen press, along with the
primary core 144 in the same manner as described above for a flame
retardant panel 100 utilizing a pre-cured primary core 108, and
additional un-cured phenolic resin is applied to the first and
second faces 110, 112 of the core 144. During the curing process,
application of pressure and heat causes the uncured phenolic resin
to flow into the rovings 148, 150 and through the reinforcements
153 formed by adjacent groupings 146, to thereby form the
reinforced phenolic ribs 140.
[0065] In practicing the invention, where the fire retardant panel
100 defines (see FIG. 1) a longitudinal axis 154 thereof, a
transverse axis 156 thereof extending substantially perpendicularly
to the longitudinal axis 154, and a thickness T thereof extending
substantially orthogonally to both the longitudinal and transverse
axes 154, 156 of the panel 100, with both the longitudinal and
transverse axes 154, 156 lying substantially within a plane defined
by the interior face 104 of the panel 100, the first and second
skins 118, 120 may include a stitched composite reinforcing
structure (not shown) of fibrous material, impregnated with
phenolic resin. As is known in the art, the reinforcing structure
of the skins 118, 120 may have first, second, and third layers,
with the first layer being disposed adjacent the primary core 108
(144) and including only substantially randomly directed fibers,
the second layer being disposed against the first layer and
comprising substantially only longitudinally directed fibers, and
the third layer being disposed against the second layer and
comprising substantially only transversely directed fibers, with
the first, second, and third layers being stitched together by
stitching extending at least partially orthogonally to the
longitudinal and transverse axes 154, 156. In embodiments of the
invention utilizing an additional skin 134, the additional skin 134
may also include a three-layered stitched composite reinforcing
structure of fibrous material, impregnated with phenolic resin, of
the type described hereinabove with regard to the first and second
skins 118, 120, with the first layer of the reinforcing structure
of the additional skin 134 being disposed against the secondary
core 132.
[0066] A flame retardant panel, according to the invention, may
further include a surfacing veil (not shown), as is known in the
art, disposed against at least one of the first, second, or
additional skins 118, 120, 134, adjacent either the exterior or
interior face 102, 104 of the flame retardant panel 100.
[0067] As illustrated in FIGS. 6A-6D, one or more of the closeouts
122, 124, 126, 128, of the first exemplary embodiment of the fire
retardant panel 100, may be machineable to include at least one
mating surface 158, such as the lap joint shown in FIGS. 6A-6D. As
shown in FIG. 1, and FIGS. 6A and 6B, the closeout 122, in the
completed panel 100, includes a pair of bores 159 extending
therethrough in a direction substantially perpendicularly to the
plane of the panel 100 defined by the longitudinal and transverse
axes 154, 156. The closeouts 122, 124, 126, 128, may also take a
variety of forms, as illustrated in FIGS. 6A-6D. FIGS. 6A-6D also
illustrate other details of various alternate embodiments of the
invention, in which the fire retardant panel 100 includes a beveled
surface, either as part of or adjacent to the closeout 122.
[0068] FIGS. 6A-6D further illustrate various alternate
embodiments, and placements of components in the fire retardant
layer. For example, in FIG. 6C, a layer of intumescent material 136
is utilized on the mating surface 158 and angled side of the panel
100, in combination with a fire retardant layer having a secondary
core and additional skin 134. In FIGS. 6A-6D, and also in FIGS.
9A-9D, as described below, the primary core of the various
alternate illustrated embodiments has been designated with
reference numeral 408, to indicate that the primary core 408 may
take the form of the exemplary cores 108, or 144, as described
hereinabove, or any other form within the scope of the
invention.
[0069] In similar fashion, the primary core 108 (144) may also
include a variety of materials, additional components, and have
configurations other than those specifically illustrated herein. In
some embodiments of the invention, the primary core 108 (144) may
include a plastic closed cell foam of polyisocyanurate material.
The primary core 108 (144) may also be fabricated from a variety of
other appropriate materials, such as balsa wood.
[0070] As shown in FIG. 2, the primary core 108 (144) may further
include at least one tapping block, including a block 162 of
reinforced phenolic material, and a metal plate 164 encapsulated
within the block 162. The tapping plate 164 is adapted to be
drilled and tapped so as to provide a mounting area, for seating
arrangements, for example, in the flame retardant panel 100.
[0071] FIGS. 7A-7E illustrate a flame retardant panel apparatus, in
the form of a flooring apparatus 200 of a conveyance, illustrated
by an under floor support frame 202 of a passenger rail car. The
flame retardant floor panel apparatus 200 includes multiple
interconnected panels, in the form of a center panel 204 and a pair
of identical, reversible, end panels 206. Each of the multiple
interconnected panels 204, 206, 206 includes an exterior face 208
thereof, adapted for attachment to the support frame 202 and an
interior face 210 thereof adapted for defining a boundary, in the
form of a floor, of a passenger compartment (not shown). In the
panel apparatus 200, all of the panels 204, 206, 206 are flame
retardant panels, constructed in accordance with the present
invention.
[0072] In general, the flame retardant panels 204, 206, 206 of the
flooring apparatus 200 are constructed in the same manner as
described hereinabove with regard to the first exemplary embodiment
of a flame retardant panel 100, according to the invention. It will
be noted, however, that the panels 204, 206 of the flooring
apparatus 200 have a first thickness T thereof in sections of the
exterior face 208 which are aligned with spaces, as illustrated at
212, which are defined by the longitudinal rails 214, 216, 218, and
cross members 220 of the support frame 202, and a second, thinner,
thickness t in sections of the flooring panels 204, 206, 206
aligned above the various members 214, 216, 218, 220 of the support
frame 220, when the flooring panels 204, 206, 206 are placed in
position on the support frame 202. This arrangement of two
thicknesses T, t is utilized in the exemplary embodiment of the
flooring apparatus 200, so that the smaller thickness t can match
the thickness, for example, three-quarters of an inch, of prior and
existing floor panels used in conveyances such as rail cars and/or
buses. The thickness T of the panels 204, 206, 206 is increased in
areas where the panels 204, 206, 206 do not rest on the support
frame 202, in order to provide room for the primary core to be made
thicker, to thereby provide increased thermal and acoustic
insulation, and increased structural stiffness in the floor panels
204, 206, 206 of the exemplary embodiment of the flooring apparatus
200, according to the invention.
[0073] In embodiments of the floor apparatus 200, wherein the floor
panels 204, 206, 206 include ribs of phenolic reinforced material
extending between a first and a second skin of the floor panels
204, 206, 206, in the manner illustrated by the ribs 140 in FIGS.
2-4 for the first exemplary embodiment 100, the ribs will
preferably be positioned to extend substantially perpendicularly
across the shorter dimension of the spaces 212 within the support
frame 202. In the flooring panels 202, 206, 206 of the exemplary
embodiment of the flooring apparatus 200, for example, all ribs
within the panels 204, 206, 206 would preferably be oriented in a
substantially longitudinal direction parallel to the longitudinal
side and middle rails 214, 216, 218.
[0074] The floor panels 204, 206, 206 may be attached to the
support frame 202 by any appropriate method, or combination of
methods. For example, the floor panels 204, 206, 206 may be
adhesively bonded to the support frame with an adhesive, such as a
moisture curing urethane. Alternatively, or in addition to
adhesively bonding the floor panels 204, 206, 206 to the support
frame 202, fasteners, such as screws, bolts, rivets, etc. may also
be utilized for attaching the floor panels 204, 206, 206 to the
support frame 202.
[0075] FIGS. 8A-8C illustrate another embodiment of a floor panel
300, for use in a flooring apparatus, according to the invention.
The flame retardant floor panel 300 is configured for attachment to
a support frame (not shown) of the type illustrated by the support
frame 202 in FIG. 7A having a series of cross members which would
be received in reduced thickness sections 302 of the panel 300. The
panel 300 also includes additional reduced thickness sections 304
configured for resting upon longitudinal rails of a support frame,
in the same manner as illustrated in FIG. 7A for the flooring
apparatus 200. Through comparison of the drawings illustrating the
flooring apparatus 200, and the flooring panel 300, it will be
appreciated that whereas the flooring panels 204, 206, 206 of the
flooring apparatus 200 had a major axis thereof oriented
substantially longitudinally with respect to the support frame 200,
the panels 300 are configured to have a major axis of the panels
300 oriented substantially transversely to the longitudinal axis of
the support frame to which the panels 300 are attached.
[0076] As shown in FIGS. 9A-9D where a flame retardant panel 100,
according to the invention, includes sections of a first and a
second thickness T, t, the layer of flame retardant material 130
may be different in the area of greater thickness T, than in the
area of lesser thickness t. For example, as shown in FIG. 9B, where
the flame retardant panel 100 is thicker, the layer of flame
retardant material may be constructed in accordance with the
embodiment illustrated in FIG. 2, while, in the areas of the
exterior face in which the panel has a lesser thickness, the layer
of flame retardant material 130 may be constructed in accordance
with the embodiment illustrated in FIG. 4. In other embodiments of
the invention, not having sections of differing thickness, the
layer of flame retardant material may be constructed differently in
various sections of the panel. Also, as indicated in FIG. 9C, where
a panel 100, according to the invention, includes a reduced
thickness section t disposed inwardly from the periphery 105 of the
panel 100, the panel 100 may include a channel-shaped structure
166, of reinforced phenolic material, or another appropriate
material.
[0077] As shown in FIG. 10, a flame retardant panel 100, according
to the invention, may include a heating element 170 attached to, or
embedded into the first skin 118 of the panel, for providing
heating of the interior surface of the panel.
[0078] As also shown in FIG. 10, a flame retardant panel 100,
according to the invention, may also include one or more conduits
180 of plastic, metal composite, or pultruded composite, for
example, embedded within the panel 100, and having first and second
openings 182, 184 into the conduit 180, through at least one of the
interior or exterior faces 102, 104 or the perimeter 105 of the
panel.
[0079] All references, including publications, patent applications,
and patents cited herein are hereby incorporated by reference to
the same extent as if each reference were individually and
specifically indicated to be incorporated by reference and were set
forth in its entirety herein.
[0080] The use of the terms "a" and "an" and "the" and similar
referents in the context of describing the invention (especially in
the context of the following claims) is to be construed to cover
both the singular and the plural, unless otherwise indicated herein
or clearly contradicted by context. The terms "comprising,"
"having," "including," and "containing" are to be construed as
open-ended terms (i.e., meaning "including, but not limited to,")
unless otherwise noted. Recitation of ranges of values herein are
merely intended to serve as a shorthand method of referring
individually to each separate value falling within the range,
unless otherwise indicated herein, and each separate value is
incorporated into the specification as if it were individually
recited herein. All methods described herein can be performed in
any suitable order unless otherwise indicated herein or otherwise
clearly contradicted by context. The use of any and all examples,
or exemplary language (e.g., "such as") provided herein, is
intended merely to better illuminate the invention and does not
pose a limitation on the scope of the invention unless otherwise
claimed. No language in the specification should be construed as
indicating any non-claimed element as essential to the practice of
the invention.
[0081] Preferred embodiments of this invention are described
herein, including the best mode known to the inventors for carrying
out the invention. Variations of those preferred embodiments may
become apparent to those of ordinary skill in the art upon reading
the foregoing description. The inventors expect skilled artisans to
employ such variations as appropriate, and the inventors intend for
the invention to be practiced otherwise than as specifically
described herein. Accordingly, this invention includes all
modifications and equivalents of the subject matter recited in the
claims appended hereto as permitted by applicable law. Moreover,
any combination of the above-described elements in all possible
variations thereof is encompassed by the invention unless otherwise
indicated herein or otherwise clearly contradicted by context.
* * * * *