U.S. patent application number 14/295169 was filed with the patent office on 2015-01-01 for composite structural panels and components.
This patent application is currently assigned to NOBLE ENVIRONMENTAL TECHNOLOGIES CORPORATION. The applicant listed for this patent is NOBLE ENVIRONMENTAL TECHNOLOGIES CORPORATION. Invention is credited to Robert Noble.
Application Number | 20150004371 14/295169 |
Document ID | / |
Family ID | 52115862 |
Filed Date | 2015-01-01 |
United States Patent
Application |
20150004371 |
Kind Code |
A1 |
Noble; Robert |
January 1, 2015 |
COMPOSITE STRUCTURAL PANELS AND COMPONENTS
Abstract
Composite panels including core layers of particular geometry
and optional first and second skin layers. The components
optionally are made from fiberboard material. The core has either a
linear geometry or made from discrete elements. In exemplary
embodiments, longitudinally extending voids extend through the
panel. Electrical or mechanical conduits may be inserted through
the longitudinally extending voids.
Inventors: |
Noble; Robert; (Encinitas,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NOBLE ENVIRONMENTAL TECHNOLOGIES CORPORATION |
SAN DIEGO |
CA |
US |
|
|
Assignee: |
NOBLE ENVIRONMENTAL TECHNOLOGIES
CORPORATION
SAN DIEGO
CA
|
Family ID: |
52115862 |
Appl. No.: |
14/295169 |
Filed: |
June 3, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61841237 |
Jun 28, 2013 |
|
|
|
Current U.S.
Class: |
428/178 ;
29/428 |
Current CPC
Class: |
E04C 2002/3444 20130101;
E04C 2002/3427 20130101; Y10T 428/24661 20150115; Y10T 29/49826
20150115; E04C 2/3405 20130101; E04C 2/521 20130101; E04C 2002/3472
20130101; E04C 2002/3455 20130101; E04C 2002/3422 20130101; E04C
2002/345 20130101; E04C 2002/3494 20130101 |
Class at
Publication: |
428/178 ;
29/428 |
International
Class: |
E04C 2/34 20060101
E04C002/34; E04C 2/52 20060101 E04C002/52; E04C 2/02 20060101
E04C002/02 |
Claims
1. A composite panel comprising: at least two inner cores made from
fiberboard material, each inner core has a defined geometry and is
layered on top of each other; and a plurality of open spaces formed
between the defined geometries of the inner cores.
2. The composite panel of claim 1 wherein the defined geometry of
the inner core is linear.
3. The composite panel of claim 1 wherein the inner core has a
discrete element geometry.
4. The composite panel of claim 2 wherein the open space forms at
least one longitudinally extending void.
5. The composite panel of claim 4 further comprising an electrical
element into the at least one longitudinally extending void.
6. The composite panel of claim 4 further comprising a mechanical
element inserted into the at least one longitudinally extending
void.
7. The composite panel of claim 3 wherein the open space forms at
least one longitudinally extending void.
8. The composite panel of claim 7 wherein the discrete elements
have a pyramid shape.
9. The composite panel of claim 7 wherein the discrete elements
have a conical shape.
10. The composite panel of claim 3 wherein the discrete elements
have a hexagonal shape.
11. A composite panel comprising: a first sheet made from
fiberboard material; a second sheet made from fiberboard material;
an inner core with a defined geometry made from fiberboard
material, wherein the first sheet is affixed to the top side of the
inner core and the second sheet is affixed to the bottom side of
the inner core; and at least one longitudinally extending void
space formed between the top and bottom sheets and the defined
geometry of the inner core.
12. The composite panel of claim 11 wherein the defined geometry of
the inner core is linear.
13. The composite panel of claim 11 wherein the defined geometry of
the inner core has a discrete element geometry.
14. The composite panel of claim 13 wherein the discrete element
geometry is conical.
15. The composite panel of claim 13 wherein the discrete element
geometry is in the shape of a pyramid.
16. The composite panel of claim 13, wherein the discrete element
geometry is hexagonal.
17. The composite panel of claim 11 further comprising one or more
inner cores and one or more sheets affixed on top of each
other.
18. A method of forming a composite panel comprising: providing a
first and second sheet made from fiberboard material; providing an
inner core made from fiberboard material with a top side and a
bottom side; affixing the first sheet to the top side of the inner
core; and affixing the second sheet to the bottom side of the inner
core.
19. The method of forming the composite panel of claim 18 wherein
the inner core has a linear geometry.
20. The method of forming the composite panel of claim 18 wherein
the inner core has a discrete element geometry.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. application No.
61/841,237, entitled, "Composite Structural Panels and Components",
and which was filed Jun. 28, 2013, the entirety of which is
referred to and incorporated herein by this reference in its
entirety.
FIELD OF THE DISCLOSURE
[0002] The disclosure that follows relates to structural panels
derived from composite materials.
BACKGROUND
[0003] Although there are a wide variety of known materials and
techniques to produce traditional structural panels, improvements
upon the materials or techniques may produce a more versatile
panel, with improved transportability and functionality. Moreover,
there is a need for materials and techniques that reduce
consumption of nonrenewable resources, and still provide cosmetic
and functional appeal. Accordingly, there is a need for structures
and techniques for assembling composite structural panels, and
which optionally are fabricated of renewable or waste
resources.
[0004] Traditional structural panels are solid pieces of material
sandwiched between two boards. These traditional panels offer
benefits such as insulation. They do not, however, provide for
plumbing through their inner cores. There is a need for panels with
hollow interiors that can provide conduits for electrical and
mechanical features.
SUMMARY
[0005] 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. In some embodiments, mechanical elements
such as ducting, wiring or other elements may be positioned within
the void spaces. Alternatively, the voids may serve as fluid
transit ducts such as for ventilation purposes.
[0006] In one embodiment of the invention, 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.
[0007] 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.
[0008] It is an object of the present invention to provide
composite panels that are lightweight yet retain a desired shape.
Due to the relatively low weight to surface area ratio, the panels
may be handled by relatively light equipment or crews. The panels
may be loaded and transported on the back of a pickup truck and be
assembled in remote locations.
[0009] Other objects of the present invention will become more
evident hereinafter in the specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The foregoing and other objects of the disclosure will be
apparent upon consideration of the following detailed description,
taken in conjunction with the accompanying drawings, in which:
[0011] FIG. 1 is an elevation view of a panel in accordance with an
embodiment of the invention;
[0012] FIG. 2 is an elevation view of an inner core in accordance
with the invention;
[0013] FIG. 3 is a perspective view of a panel in accordance with
an embodiment of the invention;
[0014] FIG. 4 is a perspective view of an inner core in accordance
with an embodiment of the invention;
[0015] FIG. 5 is a plan view of an element in accordance with an
embodiment of the invention;
[0016] FIG. 6 is a perspective view of an element in accordance
with an embodiment of the invention;
[0017] FIG. 7A is a perspective view of an inner core in accordance
with an embodiment of the invention;
[0018] FIG. 7B is a perspective view of an inner core in accordance
with an embodiment of the invention;
[0019] FIG. 8A is a plan view of an inner core in accordance with
an embodiment of the invention;
[0020] 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;
[0021] FIG. 8C is a cross-sectional view of an inner core in
accordance with an embodiment of the invention;
[0022] FIG. 9A is a perspective view of an inner core with an
embodiment of the invention;
[0023] FIG. 9B is a detail perspective view of an inner core in
accordance with an embodiment of the invention;
[0024] 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;
[0025] FIG. 10A is a perspective view of an inner core in
accordance with an embodiment of the invention;
[0026] FIG. 10B is a detail perspective view of an inner core in
accordance with an embodiment of the invention;
[0027] FIG. 10C is a top plan view of an inner core in accordance
with an embodiment of the invention;
[0028] FIG. 10D is a cross-sectional view taken along line 5-5 in
FIG. 10C of an inner core in accordance with an embodiment of the
invention;
[0029] FIG. 11A is a perspective view of an inner core in
accordance with an embodiment of the invention;
[0030] FIG. 11B is a detail perspective view of an inner core in
accordance with an embodiment of the invention;
[0031] FIG. 11C is a perspective view of an element of an inner
core in accordance with an embodiment of the invention; and
[0032] FIG. 11D is a cross-sectional view taken along lines 5-5 and
6-6 in FIG. 11B of an inner core in accordance with an embodiment
of the invention.
[0033] FIG. 12 is a perspective view of a panel in accordance with
an embodiment of the invention.
[0034] FIG. 13 is a perspective view of a panel in accordance with
an embodiment of the invention.
[0035] FIG. 14 is a perspective view of a panel in accordance with
an embodiment of the invention.
[0036] FIG. 15 is a perspective view of a panel in accordance with
an embodiment of the invention.
[0037] FIG. 16 is a perspective view of a panel in accordance with
an embodiment of the invention.
DETAILED DESCRIPTION
[0038] In the following paragraphs, embodiments will be described
in detail by way of example with reference to the accompanying
drawings, which are not drawn to scale, and the illustrated
components are not necessarily drawn proportionately to one
another. Throughout this description, the embodiments and examples
shown should be considered as exemplars, rather than as limitations
of the present disclosure. As used herein, the "present disclosure"
or "present invention" refer to any one of the embodiments
described herein, and any equivalents. Furthermore, reference to
various aspects of the invention throughout this document does not
mean that all claimed embodiments or methods must include the
referenced aspects or features.
[0039] 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. It should be
appreciated that when used as a wall panel, 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."
[0040] In the illustrated embodiment, it is seen that 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.
[0041] 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 U.S. Pat.
No. 8,297,027, entitled, "Engineered Molded Fiberboard Panels and
Methods of Making and Using the Same" and U.S. Pat. No. 8,475,894,
entitled, "Engineered Molded Fiberboard Panels, Methods of Making
the Panels, and Product Fabricated From the Panels," both of which
are referred to and incorporated herein in their entireties.
[0042] Illustrated in FIG. 2 is a cross section of an inner core
structure. In this embodiment, 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. In some embodiments, 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.
[0043] 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. In the case of a linear geometry, a
cross-sectional profile exceeds the length of panel 10. Stated
another way, 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.
[0044] Shown in FIG. 4 is a discrete geometry. The inner core
includes parallel discrete elements 27. Typically, 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. Two
examples of possible discrete geometries that can be achieved
through the present invention are shown in FIGS. 5 and 6. For
example, 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.
[0045] 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.
[0046] FIGS. 7A and 7B show a perspective view and a detailed
perspective view of inner core 20. As shown in FIGS. 7A and 7B,
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. After the top and bottom skins are affixed to the
corrugated inner core 20, open space 120 defining longitudinally
extending voids are formed between the inner core and the
skins.
[0047] Optionally mechanical or electrical elements may be
positioned within one or more of the longitudinally extending void
spaces 120 of this embodiment. Examples of such 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.
[0048] FIG. 8A 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. Larger 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.
[0049] Conversely, 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. 9A and 9B are a perspective view
and a detailed perspective view of an inner core 80 featuring a
discrete element. As shown in FIG. 9B, element 200 of inner core 80
has a pyramid-like structure with peaks 28 bordered by axially
extending sidewalls 29. For the purpose of naming and not of
limitation, this structure will be referred to as a pyramidal
embodiment. Although 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. Optionally, 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.
[0051] FIG. 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.
Similar to the corrugated structure of FIGS. 7-8, 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. Larger 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.
[0052] 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. For the purpose of naming
and not of limitation, this structure will be referred to as a
conical embodiment. Although 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. Optionally, 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.
[0053] FIG. 10C 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. Similar to the corrugated
structure of FIGS. 7-8 and the pyramidal embodiment of FIGS. 9A-9C,
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.
[0054] Another possible shape for an inner core discrete element is
shown in FIGS. 11A through 11D. In this embodiment the discrete
element 400 is hexagonally or egg-crate shaped with four axially
extending sidewalls 410 surrounding peak and valley surfaces 420.
For the purpose of naming and not of limitation, this structure
will be referred to as a hexagonal embodiment. Unlike the
previously disclosed embodiments, 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.
[0055] 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. For example,
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. Optionally 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.
[0056] 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.
[0057] If desired, additional layers of inner cores 20 may be
added. In one example illustrated in FIG. 14, four stacked inner
core layers 20 are provided. In this embodiment, 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. For
example, 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. Likewise, longitudinally extending void spaces 120 in
the y direction are formed between the two middle layers 205, 210.
Depending on the requirements and specifications of the composite
structural panel, it is possible to add additional inner core
layers to the embodiment shown in FIG. 14. For example, 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.
[0058] In other embodiments, 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. Likewise, FIG. 16 illustrates an
embodiment corresponding to that of FIG. 16, but with first and
second skins 30, 40 included.
[0059] Additional embodiments of multiple layers of discrete
element geometry inner cores with skins are possible. In some
embodiments, 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.
[0060] Many advantages of composite panels made from fiberboard
materials have been described above. An additional advantage of the
composite panels in their many embodiments is their weight. 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.
[0061] Thus, it is seen that composite structural panels and
components are provided. It should be understood that any of the
foregoing configurations and specialized components may be
interchangeably used with any of the apparatus or systems of the
preceding embodiments. Although illustrative embodiments are
described hereinabove, it will be evident to one skilled in the art
that various changes and modifications may be made therein without
departing from the scope of the disclosure. It is intended in the
appended claims to cover all such changes and modifications that
fall within the true spirit and scope of the disclosure.
* * * * *