U.S. patent number 3,876,492 [Application Number 05/362,257] was granted by the patent office on 1975-04-08 for reinforced cellular panel construction.
Invention is credited to Lawrence A. Schott.
United States Patent |
3,876,492 |
Schott |
April 8, 1975 |
Reinforced cellular panel construction
Abstract
A reinforced, light panel structure for use as a structural
module having a pair of spaced, parallel sheets separated by and
joined to a shaped insert in the form of a continuous sheet with
multiple, adjacent, closed wall, circularly cross-sectioned,
conical projections extending in spaced array in alternately
opposite directions from a common plane to provide a plurality of
contact surfaces secured to the inside surfaces of the spaced
parallel sheets.
Inventors: |
Schott; Lawrence A. (Detroit,
MI) |
Family
ID: |
23425364 |
Appl.
No.: |
05/362,257 |
Filed: |
May 21, 1973 |
Current U.S.
Class: |
52/789.1;
244/133; 244/117R; 428/178 |
Current CPC
Class: |
B32B
15/14 (20130101); B32B 17/02 (20130101); B32B
15/08 (20130101); B32B 7/12 (20130101); B32B
27/12 (20130101); B32B 27/08 (20130101); E04C
2/3405 (20130101); E04C 2002/3427 (20130101); Y10T
428/24661 (20150115); B32B 2315/085 (20130101); B32B
2607/00 (20130101); E04C 2002/3433 (20130101); E04C
2002/3438 (20130101); E04C 2002/3472 (20130101) |
Current International
Class: |
E04C
2/34 (20060101); B32b 003/12 (); E04b 002/28 ();
E04c 002/32 () |
Field of
Search: |
;161/68,69,127
;52/615 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Dier; Philip
Attorney, Agent or Firm: Barnes, Kisselle, Raisch &
Choate
Claims
1. In a panel construction module of the type having a hollow core
with a plurality of projections to each side of center and a sheet
of material on each side of said core secured on the inner side to
respective apices of said projections to provide a rigid
construction, that improvement which comprises a core of sheet
material formed outward to each side Z+ and Z- of the sheet with
conical hollow projections, the bases of which lie in contiguous
circles in the plane of said sheet and extending in a regular
pattern to a plane on each side of the base departure plane of the
sheet, each cone having substantially straight side walls from one
apex of the Z- cones to the apex of the Z+ cones in planes cutting
the core in the X and Y direction through the center of the cones,
said side walls being
2. A panel construction module as defined in claim 1 in which the
rigidifying sheets are provided with embossed deformations between
the apices and away from the plane of the sheets to provide
rigidifying
3. A panel construction as defined in claim 2 in which said
deformations comprises concave depressions between said apices.
Description
This invention relates to a panel construction and more
particularly to a structural panel that can be used for modular
assembly for many different purposes.
It is an object of the present invention to provide a panel
construction which is extremely light and inexpensive to
manufacture and one which has considerable impact strength and
resistance to bending.
Another object of the invention is to provide a panel construction
which may be used for aircraft, furniture, housing, housing walls,
ceilings, floors, shipping containers, house and freight trailers,
and for many other applications where a preformed, lightweight
panel having insulating and strength characteristics is
required.
Reference is made to U.S. Pat. No. 3,673,057 issued June 27, 1972
relating to a cellular structure. The present invention is intended
to be an improvement on the structure shown in this patent in that
the core material is more readily formed in a less expensive
process and the resulting structure is substantially stronger by
reason of the inherent nature of the core structure when combined
with the sheet envelopes.
It is therefore, an object to provide a strong, light, core
material which combines with a tension skin to provide a strong
panel material. The circularly cross-sectioned cones provide a
triangulation structure in multiple directions to rigidify the
assembly.
It is a further object to provide an improved panel construction
which can be readily formed, which will be light in weight, and
which can be adapted to varying contours by reason of its basic
construction.
Other objects and features of the invention will be apparent in the
following description and claims in which the principles of
operation together with details of construction are shown and
described in connection with the best mode presently contemplated
for the practice of the invention.
Drawings accompany the disclosure and the various views thereof may
be briefly described as:
FIG. 1, a sectional view of a completed panel.
FIG. 2, a top view of the panel showing a portion of one side
removed to illustrate the core formation.
FIG. 3, a sectional view looking into the side of the end of the
completed panel.
FIG. 4, a sectional view taken on line 4--4 of FIG. 2.
FIG. 5, a perspective view of the core element.
FIG. 6, a modified view showing fastening tabs on the truncated
ends of the conical projections.
FIG. 7, a breakaway plan view illustrating a panel construction
with a reinforced outer skin.
FIG. 8, a sectional view on line 8--8 of FIG. 7.
FIG. 9, a modified skin reinforcement design.
FIG. 10, a second modification of a skin reinforcement design.
FIG. 11, an illustration of an arched panel.
FIG. 12, a sectional view on line 12--12 of FIG. 11.
FIG. 13, an illustration of a domed panel.
FIGS. 14 and 15, sectional views on line 14--14 and 15--15 of FIG.
13.
FIGS. 16 and 17, views illustrating panel reinforcement sheets with
rounded and pointed cones.
Referring to the drawings:
In FIG. 1, it will be seen that the panel construction is formed
with two side sheets 20 and 22 and a core construction indicated
generally at 24.
The panel may be made in any number of different sizes and from
different materials depending on the load to be carried and the
weight desired. In some instances, the side sheet 20, panels 22,
can be formed of a plywood. In other instances, they may be formed
of sheet metal. In some instances, they might be formed of a cloth
or plastic sheeting having good tensile characteristics. The core
can be formed either of sheet metal of from sheet plastic, fiber
glass, and other synthetic materials. The core is formed by taking
a sheet of material and forming conical projections from each side
of a base departure plane so that alternately the projections are
up and down in both the X direction and the Y direction as shown in
FIG. 2; and as shown in FIG. 3, the projections extend in the Z
plus (Z+) direction and the Z minus (Z-) direction. The projections
are formed as closed hollow cones circular in cross section with
straight side walls as shown best in FIG. 3, and the cones are
preferably truncated to have a closed apex with a flat surface to
assist in the securing of the panels to the core. The lines which
generate the cones are preferably straight to provide a
triangulation design as shown particularly in FIGS. 1 and 3 where
the lines from the inside of the skin panels extend straight from
one panel to the other. This bridging effect results in a structure
which is very strong in resisting compression or sheer forces.
With reference to the drawings, the upwardly projecting cones are
illustrated at 26 and the downwardly projecting cones are
illustrated at 28. These cones have flat surfaces 30 which lie in a
plane which coincides with the inside of the side sheet panels 20
and 22. In the assembly, the side sheets 20 and 22 may be fastened
to the apices of the cone in various ways depending on the
materials. For example, if the core is formed from sheet metal and
the otuer sheets are metal, there could be a heat bonded, brazed,
soldered or spot welding juncture at the top of each cone. If the
core material is a plastic, the side sheets may be adhered by eith
a solvent or fusion process if the materials are compatible to this
extent or by the use of a suitable adhesive. Plywood side sheets
can be adhered to the plastic core by adhesive. In many instances,
even a plastic sheet or a paper sheet may be applied for certain
applications. The tensile strength of the skin layers is important
to the overall strength of the device.
While the walls of each cone are generally circular in
cross-section and strictly conical in the sense that the walls are
straight, as illustrated in FIGS. 1 and 3, nevertheless, the
formation of the units as illustrated in FIG. 4 provides joining
radii areas 32 which are inherent in the particular formation. This
has an advantage in that the structure can be shaped into various
curvatures in one direction or the other or in both directions so
that a structure can be formed with compound curvature as for
example, the nose of an airplane or the leading edge and end of an
airplane wing. The structure with the conial formations therefore,
has the advantage that it can be shaped in simple or compound
curves preferably before the side structures are applied so that
the side structures will maintain the configuration. The cones are
spaced in the X and Y directions, FIG. 2, so that the conical walls
are straight and continuous from apex to apex in the Z+ and Z-
directions -- FIG. 4. This is shown best in FIG. 3.
In FIG. 6, a modified structure is shown in which the end plates or
apices of the cones are perforated to provide projections 34 which
can be utilized to fasten the core structure to a molded material
such as a plastic which can be molded directly on to the cones or a
plaster wall structure, for example.
In FIG. 7, a modified construction is shown in which a skin pane 40
is provided with formed depressions 42 extending between the apices
of the inner core to reinforce the skin panel 40 against bending
between the portions where it is fastened to the apices 30 of the
core section. Where the skin panel 40 is to be covered with another
panel 20 as shown in FIG. 8, these depressions can be concave from
the outside. In other instances, they can be convex.
In FIG. 9, a modified reinforcement skin construction is shown
where a skin panel 50 has deformations from the surface in the form
of a cross, the respective bars 52 and 54 extending between the
apices of the reinforcing cones to reinforce the skin panel between
these points of contact.
In FIG. 10, another modification of a reinforced skin construction
is shown in a skin panel 60 with elongate deformations 62 formed
out of the plane of the skin panel to reinforce the skin panel
between the apices. These deformations 42, 52 and 62 can be molded
into the skin panel prior to its assembly whether the panel is made
of metal or plastic and in the case of the embodiment shown in
FIGS. 9 and 10 will constitute ridges on the surface of the panel
extending either to the outside or the inside.
In FIGS. 11 to 15, the panel is illustrated in a curved formation.
The core of the panel is so designed that it may be bent in either
a single curve in the form of an arch as shown in the component 70
of FIG. 11, sectioned in FIG. 12, or as a double compound curve as
shown in the segment 72 sectioned in FIGS. 14 and 15. The conical
construction lends itself to being shaped in either a single arched
curve or a compound curve and thus has advantages over other core
constructions which do not have this flexibility.
In FIGS. 16 and 17, there are illustrated other types of cones, one
having a rounded apex 74 as shown in FIG. 16 and one having a sharp
apex 76 as shown in FIG. 17.
The conical configuration, together with the triangulation which
results from the formation of the cores, provides an extremely
rigid structure which has great resistance against crushing and
also against bending once the side sheets are applied. In addition,
the structure has inherent resistance to any shear stresses that
might be applied to the opposing walls. Accordingly, the resultant
structure is extremely strong and relatively light in comparison to
its strength.
* * * * *