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Description  |
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to a panel having a polystyrene bead board
(STYROFOAM.TM.) core encased in a plastic film layer in a manner which
very significantly strengthens the panel. In particular, the present
invention relates to a panel wherein the polystyrene bead board
(STYROFOAM.TM.) bead board core is able to be constructed in any
configuration to enable the panel to be attached to free standing
furniture or to be used separately or with other panels to form office
dividers.
(2) Prior Art
The prior art has described several uses for panels having a foam core
encased in an outer material. Illustrative of the prior art using foam
panels are U.S. Pat. No. 5,098,059 to Sawyer; U.S. Pat. No. 2,896,271 to
Kloote et al; U.S. Pat. No. 5,086,599 to Meyerson and U.S. Pat. No.
3,230,681 to Allen et al.
Sawyer describes a concrete forming device wherein foam pieces surrounded
by a non-permeable, laminated plastic film are adapted for use in the
concrete casting and a method for forming the panels. The foam panels are
used as liners for the concrete forms.
Kloote et al describes the construction of an enclosure for a refrigerated
area using laminated panels. The panels have a polystyrene core with
polyester resin facing sheets. The panels are manufactured to have a low
coefficient of thermal transmission as well as being impervious to
moisture.
Meyerson describes a joint for connecting adjacent structural panels for
building. The panels have a polystyrene bead board (STYROFOAM.TM.) core
with an outer skin laminated to the core. Preferably, the skin is made up
of aluminum. The panels may be used for roofing or sidewalls, interior or
exterior.
Allen et al describes a means using a splice member to connect foam
laminated panels in edge to edge relationship to reduce thermal leakage.
The prior art also shows various building panels having a foam core with an
outer layer. Illustrative are U.S. Pat. No. 3,327,441 to Kelly; U.S. Pat.
No. 3,363,378 to Palfey; U.S. Pat. No. 3,563,845 to Stevens; U.S. Pat. No.
3,970,502 to Turner; U.S. Pat. No. 5,102,710 to Kaufman et al; U.S. Pat.
No. 4,641,468 to Slater; and U.S. Pat. No. 4,776,903 to Nordskog.
Kelly describes an insulated structural member comprised of a beam of rigid
plastic foam reinforced by metal bars bound therewith by a combination of
a wrapping material of low thermal conductivity and a thermosetting binder
substantially impregnated therein. The member is fixed within a main body
of insulation and then a skin is provided to cover the entire assembly.
The beams may be made of any stiff, plastic foam such as polyurethane,
polystyrene, phenolic and the like or other suitably stiff insulating
material such as preformed resin bonded fibrous glass insulation and the
like. The bars may be of any metal such as steel, aluminum and the like.
The wrapping material may be any material of low thermal conductivity
woven, non-woven or unwoven including webbed and continuous material and
filamenting wound fibrous material, such as woven glass fibers or cloth,
jute, linen, thermoplastic fibers or sheets or the like. The outer skin of
the entire assembly is made of fiberglass reinforced epoxy resin laminate
or other materials such as resin reinforced polystyrene or other plastic
laminate, metal, plywood and the like may be used.
Palfey describes sandwiched panels used for the construction of enclosures.
The panels are comprised of a core divided into sections with stiffeners
positioned between each section and face sheets on either side of the
core. The core is made from a synthetic resinous foam such as foamed
polystyrene, foamed polyurethane, foamed phenolic resinous compositions
and the like. The face sheets are made of such materials as hardboard,
fiberboard, plywood, metal sheets and the like.
Stevens describes a three-layered plastic thermally insulating panel-like
composite. The first layer is composed of a cellular polyurethane
material. The second layer is composed of an organic rigid polymeric
solid. The third layer is composed of an organic, rigid polymeric solid.
The solid is comprised of an interpolymer system of monovinyl aromatic
compound and alpha-electronegatively substituted ethane compound.
Turner describes a building panel having a foam core with an outer skin
bonded to the opposite sides thereof. Edge members extend along the entire
length of the panel and are adhesively bonded to the foam core and to the
outer skins to provide rigidity to the panel. The skins are laminated onto
the foam core by a solvent based adhesive. The solvent is blocked from
contact with the foam by a water based adhesive composition which is
compatible with the foam core. The core is made of polystyrene and the
outer skins are made of steel.
Kaufman et al describes a composite laminated decorative panel for use in
building wall systems. The panel is a three component sandwich panel
comprised of a thermoplastic shell which is laminated with a weatherable
coating, a rigid foam center and a fire blocking backerboard. The
thermoplastic shell is made of ABS (a mixture of styrene acrylonitrile
copolymer (SAN) with SAN-grafted polybutadiene rubber) although, other
materials such as PC-PVC or polystyrene can be used. The weatherable
coating is made of a high gloss, high impact sheet extrusion resin or a
acrylic film or a polyvinyldiene fluoride (PVDF). The foam center is
polyurethane rigid foam. The backerboard is preferably a non-combustible
fiber reinforced cement panel.
Slater describes a panel structure for use in building systems for the
construction of buildings. The panel is comprised of a plurality of
elongated slabs of rigid structural grade polystyrene foam insulation
material. The slabs are held together and bonded to rigid framing members
made of steel. The opposing surfaces of the panel are covered with a
variety of skins, such as plywood, sheet rock or cementitious stucco-like
material or glass reinforced acrylic resin coating.
Also of interest are U.S. Pat. No. 3,213,071 to Campbell; U.S. Pat. No.
3,281,510 to Lovret; U.S. Pat. No. 3,304,219 to Nickerson; U.S. Pat. No.
3,389,195 to Gianakos et al; U.S. Pat. No. 3,410,931 to Johnson and U.S.
Par. No. 3,468,771 to Pedlow which describe different types of laminated
foam board and different methods of manufacturing laminated foam board.
The prior art does not show a panel for use with office furniture or as a
room divider which has a polystyrene bead board (STYROFOAM.TM.) core
covered by a plastic film layer which strengthens the core to allow use of
the core without the need for additional structural support. There remains
a need for such a panel which is lightweight for easy assembly and yet
durable to withstand punctures without damage to the core of the panel.
OBJECTS
It is therefore an object of the present invention to provide a panel which
can be mounted to furniture or which can be used alone to form a divider.
Further, it is an object of the present invention to provide a panel which
is easy to install and remove. Still further, it is an object of the
present invention to provide a panel cover which is lightweight, durable
and inexpensive to manufacture.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing two panels 10 mounted together by a
connector hinge 22 and forming a space divider 100 having adjustment units
24.
FIG. 2 is a cross-sectional view of the space divider 100 of FIG. 1 along
the line 2--2 showing the core 12, the plastic film layer 14, the
decorative outer cover 18, the C-shaped attachment rail 20 of both panels
10 and the connector hinge 22.
FIG. 2A is a cross-sectional view of the space divider 100 showing an
alternate living hinge 23 between the C-shaped attachment rails 20 of the
panels 10.
FIG. 3 is a cross-sectional view of a panel 10 showing a pin 32 extending
through the decorative outer cover 18 and the plastic film layer 14 and
into the core 12 and securing an object 30 to the panel 10.
FIG. 4 is a perspective view of two panels 10 mounted onto a desk 102.
FIG. 5 is a cross-sectional view of one panel 10 and the desk 102 of FIG. 4
along the line 5--5 showing the mounting screw 28 extending through the
desk 102 and into the support plate 26 of the panel 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to a panel for use as a space divider which
comprises: a polystyrene bead board (STYROFOAM.TM.) bead board core
configured in a shape defining the panel of the space divider; a flexible
plastic film layer adhered to the core to provide an outside surface of
the panel and covering the core to thereby provide structural strength for
the core, wherein the panel is able to withstand repeated punctures in a
single hole without compromising the strength and integrity of the panel
adjacent the hole; holding means mounted adjacent the core for holding the
panel in an upright position such that the panel provides a divider for a
space; and a decorative outer layer covering at least a first portion of
the core and the plastic film layer.
Furthermore, the present invention relates to a panel for use as a space
divider which comprises: a polystyrene bead board (STYROFOAM.TM.) bead
board core configured in a shape defining the panel of the space divider;
a flexible plastic film layer adhered to the core in tension to provide an
outside surface of the panel and completely encasing the core to thereby
provide structural strength for the core, wherein the panel is able to
withstand multiple punctures without compromising the strength and
integrity of the panel; holding means mounted adjacent the core for
holding the panel in an upright position such that the panel provides a
divider for a space; a support means mounted on the core for securing the
holding means to the panel; and a decorative outer layer covering at least
a first portion of the core and the plastic film layer.
The plastic layer is preferably comprised of two sheets of a polyethylene
film layer laminated to the core which cover the top side and the bottom
side of the core. Alternately, the plastic layer can be constructed of a
rigid, nonporous polystyrene film layer. In addition, the plastic layer
can be vacuum formed onto the core. An adhesive is provided between the
core and the plastic film layer to further secure or laminate the plastic
layer to the core. The panel is preferably provided with attachment rails
which add strength to the panel and allow attachment of the panel to other
panels or to office furniture. The core of the panels can be constructed
in any configuration which allows the panels to be used in a variety of
areas including attachment to office furniture and as office dividers.
FIG. 1 shows the panel 10 of the present invention attached to another
panel 10 by a connector hinge 22 to form a space divider 100. FIGS. 2 and
3 show the specific construction of the panel 10 comprising a polystyrene
bead board (STYROFOAM.TM.) bead board core 12 covered in a rigid plastic
film layer 14, both of which are at least partially covered by a
decorative outer layer 18. The polystyrene bead board (STYROFOAM.TM.) bead
board core 12 is similar to that commonly used commercially. The bead
board core 12 has a top side 12A and a bottom side 12B with edges 12C
around the perimeter. The density of the core 12 is such as to allow the
core 12 to be lightweight while still providing the necessary structural
strength. In the preferred embodiment, a 2 to 3 lb/cubic foot board is
used for the core 12 in order to achieve the desired density. The
thickness of the core 12 may vary depending on the overall size of the
panel 10 and the specific use for the panel 10. In general, the thickness
of the core 12 is between about 1/2 and 4 inches. A C-shaped attachment
rail 20 (to be described hereinafter) may be mounted to the core 12 to
provide additional strength to the panel 10 and to allow attachment of the
panel 10 to other panels 10 (FIG. 2) and to other furniture such as a desk
102 (FIG. 5). The core 12 is able to be constructed in any configuration
depending upon the particular use for the panel 10. The ability to
construct the core 12 in any configuration significantly increases the
versatility of the panels 10.
The rigid plastic film layer 14 is uniformly adhered to the core 12 and
completely encases the core 12. The plastic film 14 preferably covers the
top side 12A and the bottom side 12B and leaves the edges 12C of the core
12 uncovered (FIGS. 2 and 3). By covering the core 12 in a plastic layer
14 the strength of the core 12 is increased and the structural integrity
of the core 12 is protected. The plastic layer 14 preferably has a uniform
thickness of approximately between 0.010 and 0.020 inches around the core
12. The plastic film layer 14 is considered to be "rigid" although, the
thinness of the plastic layer 14 allows the plastic layer 14 to flex prior
to attachment. The plastic layer 14 however preferably is not able to be
stretched or expanded without heating. The plastic layer 14 provides a
protective skin around the core 12 which provides extra strength to the
core 12 and enables the panel 10 to be used as a tack board for objects 30
(FIG. 3). The plastic layer 14 allows the panel 10 to be used as a tack
board to mount objects 30 which are heavier than those normally mounted on
a tack board by a pin 32. The plastic layer 14 encloses around and cams
against the pin 32, mounted in the opening (not shown) in the core 12.
Once the pin 32 is inserted into the plastic film layer 14 and the core
12, the plastic film layer 14 secures the pin 32 in the opening and
prevents the pin 32 from falling out of the panel 10 (FIG. 3). The plastic
layer 14 enclosed around the inserted pin 32 also enables the pin 32 to
support heavier objects 30. The plastic layer 14 continues to enclose
around the pin 32 in the opening even after the pin 32 has been inserted
and withdrawn from the opening multiple times. Thus, the plastic film
layer 14 allows the same opening in the core 12 to be used repeatedly.
This increases the useful life of the panel 10. The plastic layer 14 also
protects the structural integrity of the core 12 and holds the core 12
together even after multiple punctures have been made in the plastic layer
14 and core 12 of the panel 10 in the same opening or in multiple adjacent
openings (not shown). Further, the plastic layer 14 increases the
durability of the core 12 by reducing the possibility of accidental
surface damage to the core 12 such as chipping.
In the preferred embodiment, the plastic film layer 14 is comprised of a
first sheet 14A and a second sheet 14B. As shown in FIGS. 2 and 3, the
first sheet 14A covers the top side 12A of the core 12 and extends to the
edges 12C of the core 12. The second sheet 14B covers the bottom side 12B
of the core 12 to the edges 12C. Preferably, the first sheet 14A is of a
size such as to completely cover the top side 12A of the core 12 but not
such that the ends 14C of the first sheet 14A extend over the edges 12C of
the core 12. Likewise, the ends 14D of the second sheet 14B preferably do
not extend over the edges 12C of the core 12 such as to cover the edges
12C of the core 12. The first and second sheets 14A and 14B are preferably
laminated onto the core 12. Cold forming of the sheets 14A and 14B onto
the core 12 is less expensive than other methods such as vacuum forming
which requires heating of the plastic layer 14. Laminating the sheets 14A
and 14B onto the core 12 also allows recycled plastic layers to be used
which also reduces the cost.
In two alternate embodiments (FIG. 5), first and second extended sheets
extend beyond the edge 12C of the core 12 such that ends of the sheets
overlap at the edges 12C of the core 12. The first extended sheet is of a
size as to completely encase the top side 12A of the core 12 and to extend
over a majority of the surface of the edges 12C but not such that the ends
of the first extended sheet extend beyond the edges 12C of the core 12.
Likewise, the ends of the second extended sheet preferably do not extend
beyond the edges 12C of the core 12 such as to overlap the first extended
sheet on the top side 12A of the core 12. Thus, preferably only the ends
of the extended sheets overlap at the edges 12C of the core 12. In the
first alternate embodiment, the ends of the extended sheets are vacuum
formed around the edges 12C of the core 12. In the second alternate
embodiment, the extended sheets are vacuum formed completely around the
entire core 12. In both alternate embodiments, the extended sheets are
vacuum formed over the support plates 26, if provided (to be described in
detail hereinafter). Vacuum forming the extended sheets over the support
plates 26 adds strength to the panel 10 at the support plates 26 and
securely mounts the support plates 26 onto the core 12. In addition,
vacuum forming the film layer 14 over the support plates 26 eliminates the
need to use additional means to secure the support plates 26 onto the core
12. However, additional attachment means may be used, in which case the
vacuum formed plastic layer mainly provides additional strength at the
edges 12C and increases the overall strength of the panel 10.
The plastic film layer 14 is preferably made of a recycled polyethylene
such as PETG sold by P. C. Plastics, Itasca, Ill., or alternately, a high
impact, regrind polystyrene such as that manufactured by Primex Plastics,
Richmond, Ind. The polyethylene is used particularly when the plastic film
layer 14 is vacuum formed onto the core 12. In addition, the polyethylene
is less susceptible to the effects of ultra violet radiation and is useful
where the panel 10 comes in contact with sunlight. One of the advantages
of using polystyrene is that regrind polystyrene is less expensive than
polyethylene and the lower quality of the regrind polystyrene is
satisfactory for most uses of the panels 10. In addition, the regrind
polystyrene is more rigid than the polyethylene. The type of material used
to construct the plastic film layer 14 can be varied depending on the
specific use of the panels 10 and the particular building codes in the
area where the panels 10 are to be used. For example, low smoke or fire
resistant plastics may be needed for panels 10 used in areas which require
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