US3876492A - Reinforced cellular panel construction - Google Patents

Reinforced cellular panel construction Download PDF

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US3876492A
US3876492A US362257A US36225773A US3876492A US 3876492 A US3876492 A US 3876492A US 362257 A US362257 A US 362257A US 36225773 A US36225773 A US 36225773A US 3876492 A US3876492 A US 3876492A
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core
sheet
panel
cones
plane
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Lawrence A Schott
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
    • B32B2315/08—Glass
    • B32B2315/085—Glass fiber cloth or fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
    • E04C2002/3411—Dimpled spacer sheets
    • E04C2002/3427—Dimpled spacer sheets with conical dimples
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
    • E04C2002/3411—Dimpled spacer sheets
    • E04C2002/3433—Dimpled spacer sheets with dimples extending from both sides of the spacer sheet
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
    • E04C2002/3411—Dimpled spacer sheets
    • E04C2002/3433—Dimpled spacer sheets with dimples extending from both sides of the spacer sheet
    • E04C2002/3438—Dimpled spacer sheets with dimples extending from both sides of the spacer sheet with saddle-shaped dimples, e.g. eggcrate type spacer sheets
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
    • E04C2002/3472—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets with multiple layers of profiled spacer sheets
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24628—Nonplanar uniform thickness material
    • Y10T428/24661—Forming, or cooperating to form cells

Definitions

  • 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.
  • 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.
  • FIG. I 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 88 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. I2 a sectional view on line 12l2 of FIG. II.
  • FIG. 13 an illustration of a domed panel.
  • FIGS. 14 and 15 sectional views on line 14-14 and II5 of FIG. 13.
  • FIGS. 16 and 17 views illustrating panel reinforcement sheets with rounded and pointed cones.
  • 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.
  • 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 (2+) 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. I 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.
  • 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.
  • 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 weldingjuncture 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.
  • each cone While the walls of each cone are generally circular in crosssection 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 2+ and 2- directions FIG. 4. This is shown best in FIG. 3.
  • 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.
  • 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 of the core section.
  • these depressions can be concave from the outside. In other instances. they can be convex.
  • FIG. 9 a modified reinforcement skin construction is shown where a skin panel 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.
  • FIG. 10 another modification of a reinforced skin construction is shown in a skin panel with elongate deformations 62 formed out of the plane of the skin panel to reinforce the skin panel between the apices.
  • 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 [0 will constitute ridges on the surface of the panel extending either to the outside or the inside.
  • 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. I2. or as a double compound curve as shown in the segment 72 sectioned in FIGS. I4 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.
  • FIGS. 16 and 17. there are illustrated other types of cones. one having a rounded apex 74 as shown in FIG. I6 and one having a sharp apex 76 as shown in FIG. I7.
  • 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 crashing and also against bending once the side sheets are applied.
  • 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.
  • 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
  • improvement which comprises a core of sheet material formed outward to each side 2+ 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 disposed at a substantial angle to the departure plane.
  • a panel construction as defined in claim 2 in which said deformations comprises concave depressions between said apices.

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.

Description

United States Patent Schott Apr. 8,1975
REINFORCED CELLULAR PANEL CONSTRUCTION [76] Inventor: Lawrence A. Schott. 15940 Warwick. Detroit. Mich. 48223 [22] Filed: May 2]. 1973 [2]] Appl. No.1 362.257
[52] U.S. Cl. it'd/68: 52/615; lfil/IZ? lSll Int. Cl. B32b 3/12: E04h 2/28; EU4c 2/32 [58} Field of Search Nil/68. 69. I27; 52/615 [56} References Cited UNITED STATES PATENTS l-llljl-Jh 9/1949 Scurlock lbl/l27 X 183L688 4/1958 Knox Nil/(19 X 3.025.935 3/1962 Ensrud et al 52/hl5 X 3.525.663 8/l97l) Hale lbl/h) X Primary E.\'uminvrPhilip Dier Attorney. Agent. or FirmBarnes. Kissclle. Raisch 81 Choate (57] 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.
3 Claims. l7 Drawing Figures REINFORCED CELLULAR PANEL CONSTRUCTION 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 crosssectioned 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. I. 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 88 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. I2, a sectional view on line 12l2 of FIG. II.
FIG. 13, an illustration of a domed panel.
FIGS. 14 and 15, sectional views on line 14-14 and II5 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 (2+) 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. I 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 weldingjuncture 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 crosssection 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 2+ and 2- 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 of the core section. Where the skin panel 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 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 ofa reinforced skin construction is shown in a skin panel 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 [0 will constitute ridges on the surface of the panel extending either to the outside or the inside.
In FIGS. I] 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. I2. or as a double compound curve as shown in the segment 72 sectioned in FIGS. I4 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. I6 and one having a sharp apex 76 as shown in FIG. I7.
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 crashing 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.
I claim:
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 2+ 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 disposed at a substantial angle to the departure plane.
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 structure.
3. A panel construction as defined in claim 2 in which said deformations comprises concave depressions between said apices.

Claims (3)

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.
US362257A 1973-05-21 1973-05-21 Reinforced cellular panel construction Expired - Lifetime US3876492A (en)

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US4411121A (en) * 1981-02-02 1983-10-25 Tate Architectural Products, Inc. Structural member with truncated conical portion and composite panel including same
US4631221A (en) * 1984-04-05 1986-12-23 Hoechst Aktiengesellschaft Sheet-like sandwich molding
DE3729854A1 (en) * 1986-09-11 1988-03-17 Donn Inc INCREASED FLOOR PANEL AND METHOD FOR THE PRODUCTION THEREOF
US4794742A (en) * 1986-03-19 1989-01-03 Henderson Charles E Multi-conic shell and method of forming same
FR2621677A1 (en) * 1987-10-13 1989-04-14 Heuliez Henri France Design Rigid structure intended for producing three-dimensional elements or panels
US4856175A (en) * 1986-09-11 1989-08-15 Usg Interiors, Inc. Method of manufacturing elevated floor panels
US4906508A (en) * 1988-09-28 1990-03-06 Karl Blankenburg Molded structural module and process for making the same
WO1990015905A2 (en) * 1989-06-19 1990-12-27 Hilmar Werner Construction system consisting of moulded bricks and light supporting frameworks
US5182158A (en) * 1990-02-02 1993-01-26 Schaeffer Bernarr C Lightweight sandwich panel
EP0549499A1 (en) * 1991-12-26 1993-06-30 Lucien Poincelet Means for producing floors or other sandwich panels and elements used for their construction
FR2687950A1 (en) * 1991-12-26 1993-09-03 Poincelet Lucien Device for producing flooring (floorboards) or other panels of the sandwich type and elements used for constructing them
US5242735A (en) * 1991-10-17 1993-09-07 Karl Blankenburg Structural module
US5244745A (en) * 1992-04-16 1993-09-14 Aluminum Company Of America Structural sheet and panel
US5399406A (en) * 1993-02-05 1995-03-21 Sky Aluminium Co., Ltd. Paneling material and composite panel using the same
US5398889A (en) * 1994-02-22 1995-03-21 Furon Company Aircraft fuselage lining system
WO1997017195A1 (en) * 1995-11-06 1997-05-15 Pittman Douglas E High strength, lightweight pressurized vehicle skin structure
US5643656A (en) * 1995-08-14 1997-07-01 Lin; Tso Nan Packing cushion board
US5766774A (en) * 1994-06-20 1998-06-16 Masonite Corporation Molded core component
US5863637A (en) * 1994-12-29 1999-01-26 Ergomat A/S Mat as a support for persons in a standing working posture
US6200664B1 (en) 1999-11-01 2001-03-13 Ward Figge Explosion barrier
US6221463B1 (en) * 1998-07-08 2001-04-24 Eugene W. White Three-dimensional film structures and methods
ES2156720A1 (en) * 1999-03-31 2001-07-01 Mecanizaciones Aeronauticas S Metal structure applicable to external aeromotor casings
US20040028887A1 (en) * 2002-08-06 2004-02-12 Messinger Ross Haynes Sandwich type construction structural panel having foam tube core
US20040096628A1 (en) * 2000-12-14 2004-05-20 Werner Saathoff Composite panel, preferably of plastic, and method for its production
US20040170808A1 (en) * 2002-12-10 2004-09-02 Gary Lascelles Composite articles formed from sheets having interconnecting ridges
US20050084703A1 (en) * 2001-12-21 2005-04-21 Michael Ashmead Structural component
US6939599B2 (en) 1996-09-13 2005-09-06 Brian H. Clark Structural dimple panel
US20050281987A1 (en) * 2004-06-18 2005-12-22 Eads Deutschland Gmbh Impact-absorbing structural component
US20060225627A1 (en) * 2005-04-08 2006-10-12 Steelcase Development Corporation Work surface, edge treatment and method for configuring work surface
US20070020441A1 (en) * 2005-07-22 2007-01-25 Hongseong Industrial Co., Ltd Core for a sandwich panel manufactured by deep drawing and a sandwich panel thereby
US20070243408A1 (en) * 2005-11-22 2007-10-18 Straza George C P Formed core sandwich structure and method and system for making same
US20070257032A1 (en) * 2004-01-20 2007-11-08 Bradford Company Lightweight Stackable Horizontal Dispensing Container
US7389612B1 (en) * 2001-08-09 2008-06-24 Fischbeck Richard D Geodesic structure
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US20100140979A1 (en) * 2007-03-07 2010-06-10 Alcoa Inc. Pedestrian safe automotive hood having reinforcing foam
WO2010106558A1 (en) * 2009-03-17 2010-09-23 Dipiemme Dies And Plastic Machinery S.R.L. Board-shaped multi -layer structural element
WO2010138066A1 (en) 2009-05-26 2010-12-02 Ecopals Ab Sandwich structured construction element
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US20120175206A1 (en) * 2010-12-10 2012-07-12 Skydex Technologies, Inc. Interdigitated Cellular Cushioning
US8835016B2 (en) * 2012-03-14 2014-09-16 Celltech Metals, Inc. Optimal sandwich core structures and forming tools for the mass production of sandwich structures
WO2014172057A1 (en) * 2013-04-18 2014-10-23 Viconic Defense Inc. Recoiling energy absorbing system
US8990987B2 (en) 2011-06-07 2015-03-31 Skydex Technologies, Inc. Collapsible layered cushion
US20150107005A1 (en) * 2013-10-18 2015-04-23 Terrence Lee Schneider Sports equipment that employ force-absorbing elements
US20150233118A1 (en) * 2012-08-24 2015-08-20 Alexis Chermant Sheet for Structural Material Core, Core and Structural Material Comprising Such a Sheet
US9279258B2 (en) 2013-04-18 2016-03-08 Viconic Defense Inc. Recoiling energy absorbing system with lateral stabilizer
US9528280B2 (en) 2013-04-18 2016-12-27 Viconic Sporting Llc Surface underlayment system with interlocking resilient anti-slip shock tiles
US9925736B2 (en) 2013-12-13 2018-03-27 Celltech Metals, Inc. Sandwich structure
US10112248B2 (en) 2014-09-09 2018-10-30 Celltech Metals, Inc. Method of creating a bonded structure and apparatuses for same
US10144582B2 (en) 2016-05-11 2018-12-04 Celltech Metals, Inc. Cargo container apparatus including a sandwich structure and a track
US20190017270A1 (en) * 2017-07-13 2019-01-17 The Pro Design Group Structural panel
US10220736B2 (en) 2016-10-25 2019-03-05 Viconic Defense Inc. Seat impact energy absorbing system
US10266098B1 (en) 2017-12-21 2019-04-23 Celltech Metals, Inc. Cargo transportation system including a sandwich panel and a channel
US10363974B2 (en) 2014-03-26 2019-07-30 Celltech Metals Inc. Container apparatus including a sandwich structure
US10369739B2 (en) 2013-04-18 2019-08-06 Viconic Sporting Llc Surface underlayment system with interlocking resilient assemblies of shock tiles
US10507875B1 (en) 2018-12-21 2019-12-17 Celltech Metals Inc. Trailer wall including logistics post
US10683619B2 (en) * 2018-04-03 2020-06-16 Valery Tsimmerman Trestle mat construction panel configured for use with building equipment and a method of manufacture and/or use thereof
US10710328B2 (en) 2014-04-22 2020-07-14 Celltech Metals, Inc. Wheeled trailer sandwich structure including grooved outer sheet
US10788091B2 (en) 2017-08-22 2020-09-29 Oakwood Energy Management, Inc. Mass-optimized force attenuation system and method
US20200325690A1 (en) * 2019-04-10 2020-10-15 Infinex Holding Gmbh Carrier plate for a floor, wall or ceiling structure
US10982451B2 (en) 2018-11-07 2021-04-20 Viconic Sporting Llc Progressive stage load distribution and absorption underlayment system
US20220314577A1 (en) * 2019-07-30 2022-10-06 Econcore N.V. Underlayment
US11585102B2 (en) 2018-11-07 2023-02-21 Viconic Sporting Llc Load distribution and absorption underpayment system

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Cited By (88)

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Publication number Priority date Publication date Assignee Title
US4411121A (en) * 1981-02-02 1983-10-25 Tate Architectural Products, Inc. Structural member with truncated conical portion and composite panel including same
DE3126948A1 (en) * 1981-07-08 1983-07-14 Manfred Klaus 8858 Neuburg Schertler Process and device for producing a flat composite material
US4631221A (en) * 1984-04-05 1986-12-23 Hoechst Aktiengesellschaft Sheet-like sandwich molding
US4794742A (en) * 1986-03-19 1989-01-03 Henderson Charles E Multi-conic shell and method of forming same
DE3729854A1 (en) * 1986-09-11 1988-03-17 Donn Inc INCREASED FLOOR PANEL AND METHOD FOR THE PRODUCTION THEREOF
US4753058A (en) * 1986-09-11 1988-06-28 Donn Incorporated Elevated floor panel and method of manufacturing same
US4856175A (en) * 1986-09-11 1989-08-15 Usg Interiors, Inc. Method of manufacturing elevated floor panels
FR2621677A1 (en) * 1987-10-13 1989-04-14 Heuliez Henri France Design Rigid structure intended for producing three-dimensional elements or panels
US4906508A (en) * 1988-09-28 1990-03-06 Karl Blankenburg Molded structural module and process for making the same
WO1990015905A2 (en) * 1989-06-19 1990-12-27 Hilmar Werner Construction system consisting of moulded bricks and light supporting frameworks
WO1990015905A3 (en) * 1989-06-19 1991-06-13 Hilmar Werner Construction system consisting of moulded bricks and light supporting frameworks
US5182158A (en) * 1990-02-02 1993-01-26 Schaeffer Bernarr C Lightweight sandwich panel
US5242735A (en) * 1991-10-17 1993-09-07 Karl Blankenburg Structural module
EP0549499A1 (en) * 1991-12-26 1993-06-30 Lucien Poincelet Means for producing floors or other sandwich panels and elements used for their construction
FR2685663A1 (en) * 1991-12-26 1993-07-02 Poincelet Lucien COHERENT STRUCTURES USING FLOORS OR OTHER SURFACES.
FR2687950A1 (en) * 1991-12-26 1993-09-03 Poincelet Lucien Device for producing flooring (floorboards) or other panels of the sandwich type and elements used for constructing them
US5244745A (en) * 1992-04-16 1993-09-14 Aluminum Company Of America Structural sheet and panel
US5399406A (en) * 1993-02-05 1995-03-21 Sky Aluminium Co., Ltd. Paneling material and composite panel using the same
US5398889A (en) * 1994-02-22 1995-03-21 Furon Company Aircraft fuselage lining system
WO1995022487A1 (en) * 1994-02-22 1995-08-24 Furon Company Aircraft fuselage lining system
US5766774A (en) * 1994-06-20 1998-06-16 Masonite Corporation Molded core component
US5863637A (en) * 1994-12-29 1999-01-26 Ergomat A/S Mat as a support for persons in a standing working posture
US5643656A (en) * 1995-08-14 1997-07-01 Lin; Tso Nan Packing cushion board
WO1997017195A1 (en) * 1995-11-06 1997-05-15 Pittman Douglas E High strength, lightweight pressurized vehicle skin structure
US5716693A (en) * 1995-11-06 1998-02-10 Pittman; Douglas E. High strength, lightweight pressurized structure for use as the skin of a spacecraft or other vehicle
US6074509A (en) * 1995-11-06 2000-06-13 Pittman; Douglas E. High strength, lightweight pressurized structure for use as the skin of a spacecraft or other vehicle
US6939599B2 (en) 1996-09-13 2005-09-06 Brian H. Clark Structural dimple panel
US6221463B1 (en) * 1998-07-08 2001-04-24 Eugene W. White Three-dimensional film structures and methods
ES2156720A1 (en) * 1999-03-31 2001-07-01 Mecanizaciones Aeronauticas S Metal structure applicable to external aeromotor casings
US6200664B1 (en) 1999-11-01 2001-03-13 Ward Figge Explosion barrier
US20040096628A1 (en) * 2000-12-14 2004-05-20 Werner Saathoff Composite panel, preferably of plastic, and method for its production
US7389612B1 (en) * 2001-08-09 2008-06-24 Fischbeck Richard D Geodesic structure
US20050084703A1 (en) * 2001-12-21 2005-04-21 Michael Ashmead Structural component
US20040028887A1 (en) * 2002-08-06 2004-02-12 Messinger Ross Haynes Sandwich type construction structural panel having foam tube core
US7371451B2 (en) 2002-08-06 2008-05-13 The Boeing Company Sandwich type construction structural panel having foam tube core
US20040170808A1 (en) * 2002-12-10 2004-09-02 Gary Lascelles Composite articles formed from sheets having interconnecting ridges
US7090911B2 (en) 2002-12-10 2006-08-15 Gary Lascelles Composite articles formed from sheets having interconnecting ridges
US20090120827A1 (en) * 2004-01-20 2009-05-14 Bradford Company Lightweight Stackable Horizontal Dispensing Container
US7503462B2 (en) * 2004-01-20 2009-03-17 Bradford Company Lightweight stackable horizontal dispensing container
US20070257032A1 (en) * 2004-01-20 2007-11-08 Bradford Company Lightweight Stackable Horizontal Dispensing Container
US7644831B2 (en) 2004-01-20 2010-01-12 Bradford Company Lightweight stackable horizontal dispensing container
US7644830B2 (en) 2004-01-20 2010-01-12 Bradford Company Lightweight stackable horizontal dispensing container with braces
US20080156797A1 (en) * 2004-01-20 2008-07-03 Bradford Company Lightweight Stackable Horizontal Dispensing Container With Braces
US20050281987A1 (en) * 2004-06-18 2005-12-22 Eads Deutschland Gmbh Impact-absorbing structural component
US7566489B2 (en) * 2004-06-18 2009-07-28 Eads Deutschland Gmbh Impact-absorbing structural component
US20060225627A1 (en) * 2005-04-08 2006-10-12 Steelcase Development Corporation Work surface, edge treatment and method for configuring work surface
US20070020441A1 (en) * 2005-07-22 2007-01-25 Hongseong Industrial Co., Ltd Core for a sandwich panel manufactured by deep drawing and a sandwich panel thereby
US20070243408A1 (en) * 2005-11-22 2007-10-18 Straza George C P Formed core sandwich structure and method and system for making same
US8052198B2 (en) 2007-03-07 2011-11-08 Alcoa Inc. Pedestrian safe automotive hood having reinforcing foam
US20100140979A1 (en) * 2007-03-07 2010-06-10 Alcoa Inc. Pedestrian safe automotive hood having reinforcing foam
DE102008057973A1 (en) 2008-11-19 2010-05-20 Shelter And Roam Design Consulting space cell
WO2010106558A1 (en) * 2009-03-17 2010-09-23 Dipiemme Dies And Plastic Machinery S.R.L. Board-shaped multi -layer structural element
WO2010138066A1 (en) 2009-05-26 2010-12-02 Ecopals Ab Sandwich structured construction element
US9079377B2 (en) 2009-05-26 2015-07-14 Ecopals Ab Sandwich structured construction element
WO2011070362A1 (en) * 2009-12-10 2011-06-16 David Woolstencroft Floor/wall structure
US20120175206A1 (en) * 2010-12-10 2012-07-12 Skydex Technologies, Inc. Interdigitated Cellular Cushioning
US10197125B2 (en) 2010-12-10 2019-02-05 Skydex Technologies, Inc. Interdigitated cellular cushioning
US8915339B2 (en) * 2010-12-10 2014-12-23 Skydex Technologies, Inc. Interdigitated cellular cushioning
US8990987B2 (en) 2011-06-07 2015-03-31 Skydex Technologies, Inc. Collapsible layered cushion
US9492018B2 (en) 2011-06-07 2016-11-15 Skydex Technologies, Inc. Collapsible layered cushion
US8835016B2 (en) * 2012-03-14 2014-09-16 Celltech Metals, Inc. Optimal sandwich core structures and forming tools for the mass production of sandwich structures
US20150233118A1 (en) * 2012-08-24 2015-08-20 Alexis Chermant Sheet for Structural Material Core, Core and Structural Material Comprising Such a Sheet
US9194136B2 (en) 2013-04-18 2015-11-24 Viconic Defense Inc. Recoiling energy absorbing system
US9528280B2 (en) 2013-04-18 2016-12-27 Viconic Sporting Llc Surface underlayment system with interlocking resilient anti-slip shock tiles
US9739053B2 (en) 2013-04-18 2017-08-22 Viconic Defense Inc. Multi-tiered recoiling energy absorbing system with lateral stabilizer
US9279258B2 (en) 2013-04-18 2016-03-08 Viconic Defense Inc. Recoiling energy absorbing system with lateral stabilizer
WO2014172057A1 (en) * 2013-04-18 2014-10-23 Viconic Defense Inc. Recoiling energy absorbing system
US10369739B2 (en) 2013-04-18 2019-08-06 Viconic Sporting Llc Surface underlayment system with interlocking resilient assemblies of shock tiles
US10350477B2 (en) * 2013-10-18 2019-07-16 Composite Technology Concepts, Llc Sports equipment that employ force-absorbing elements
US20150107005A1 (en) * 2013-10-18 2015-04-23 Terrence Lee Schneider Sports equipment that employ force-absorbing elements
US9925736B2 (en) 2013-12-13 2018-03-27 Celltech Metals, Inc. Sandwich structure
US10363974B2 (en) 2014-03-26 2019-07-30 Celltech Metals Inc. Container apparatus including a sandwich structure
US10710328B2 (en) 2014-04-22 2020-07-14 Celltech Metals, Inc. Wheeled trailer sandwich structure including grooved outer sheet
US10112248B2 (en) 2014-09-09 2018-10-30 Celltech Metals, Inc. Method of creating a bonded structure and apparatuses for same
US10144582B2 (en) 2016-05-11 2018-12-04 Celltech Metals, Inc. Cargo container apparatus including a sandwich structure and a track
US10220736B2 (en) 2016-10-25 2019-03-05 Viconic Defense Inc. Seat impact energy absorbing system
US10752137B2 (en) 2016-10-25 2020-08-25 Viconic Defense Inc. Seat impact energy absorbing system
US10794058B2 (en) * 2017-07-13 2020-10-06 The Pro Design Group Structural panel
US20190017270A1 (en) * 2017-07-13 2019-01-17 The Pro Design Group Structural panel
US10788091B2 (en) 2017-08-22 2020-09-29 Oakwood Energy Management, Inc. Mass-optimized force attenuation system and method
US10266098B1 (en) 2017-12-21 2019-04-23 Celltech Metals, Inc. Cargo transportation system including a sandwich panel and a channel
US10683619B2 (en) * 2018-04-03 2020-06-16 Valery Tsimmerman Trestle mat construction panel configured for use with building equipment and a method of manufacture and/or use thereof
US10982451B2 (en) 2018-11-07 2021-04-20 Viconic Sporting Llc Progressive stage load distribution and absorption underlayment system
US11585102B2 (en) 2018-11-07 2023-02-21 Viconic Sporting Llc Load distribution and absorption underpayment system
US10507875B1 (en) 2018-12-21 2019-12-17 Celltech Metals Inc. Trailer wall including logistics post
US20200325690A1 (en) * 2019-04-10 2020-10-15 Infinex Holding Gmbh Carrier plate for a floor, wall or ceiling structure
US11746539B2 (en) * 2019-04-10 2023-09-05 Infinex Holding Gmbh Carrier plate for a floor, wall or ceiling structure
US20220314577A1 (en) * 2019-07-30 2022-10-06 Econcore N.V. Underlayment

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