Lightweight panel structure - Patent Review 5875596

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FIELD OF THE INVENTION

This invention relates to panel structures or assemblies such as those which are used as space dividers and screens for sub-dividing offices and other space.

BACKGROUND OF THE INVENTION

Panel assemblies for use in sub-dividing office and other space have typically been constructed from elongate frame members. The frame members may be made from extruded aluminium or rolled sheet metal. The central panel structure which extends between the frame members is an opaque barrier member thereby providing some privacy. A plurality of panel assemblies may be secured together to define a space which has some degree of privacy, depending upon the size of the panels and the number of panels which are assembled together. (See for example U.S. Pat. No. 5,491,943 to Vondrejs et al).

The central panel member may be designed for various requirements. For example, it may be sub-divided it one or more units and may include channels for wiring (e.g. AC wiring and/or communication wiring).

Saylor et al discloses a sound absorbing panel. The panel has a ridged rectangular frame and a core structure which is disposed within the region bounded by the frame. The core comprises at least one honeycomb layer with thin facing sheets disposed on and fixedly secured to the opposed sides of the rectangular frame. A plurality of openings are formed in either or both of the skins so that approximately a single opening will communicate with a single cell of the honeycomb layer. The facing sheets are disclosed as being made from thin sheet metal (see the abstract and column 4, lines 59-68).

U.S. Pat. No. 4,310,995 discloses a panel assembly which also includes a honeycomb core. The panel assembly includes an exterior frame member. Foam material defines an interior perimeter extending between the honeycomb layer an the exterior frame member. As shown in the drawings of this patent, the side panels are constructed from a plurality of layers of planer and corrugated material.

U.S. Pat. No. 4,437,278 discloses a wall partition having an interior honeycomb member and opposed spaced panels which may be made from plastic laminate, hardboard or wood veneer (column 2, lines 5-11).

U.S. Pat. No. 4,667,450 discloses a wall panel having an interior honeycomb construction. The opposed side faces of the panel are preferably constructed from gypsum board sheets (column 7, lines 34-35).

The honeycomb core of these various patents provides a lightweight member to the panel assembly. However, one disadvantage of some of these constructions is that the opposed side walls are constructed from relatively heavy materials. For example, U.S. Pat. No. 4,084,367 (Saylor et al) utilizes sheet metal as the side panels while U.S. Pat. No. 4,667,450 utilizes drywall. Accordingly, the benefits from using a lightweight honeycomb filler is lost by the use of such heavy construction materials. Accordingly, overall, the panel is not of a lightweight construction.

A further disadvantage of some of the constructions is that the material which is used for the opposed side walls is relatively expensive. As stated above, U.S. Pat. No. 4,084,367 utilizes sheet metal while U.S. Pat. No. 4,667,450 utilizes drywall. In addition, U.S. Pat. No. 4,437,278 utilizes plastic laminate, hardboard or wood veneer, each of which is a relatively expensive building product. Further, U.S. Pat. No. 4,310,995 uses a multi-wall laminated construction. The manufacturer of such a construction requires multiple manufacturing steps and accordingly this adds to the overall cost of the unit.

SUMMARY OF THE PRESENT INVENTION

In accordance to the instant invention there is provided a panel structure comprising a frame members defining the perimeter of the panel structure, the frame members having a first side facing outwardly of the panel structure and an opposed side facing inwardly, and a panel member extending between the frame members and engage therewith. The panel member comprises an inner honeycomb core constructed from cellulosic material and having a pair of opposed side faces and, a pair of opposed side panel members having a first side facing outwardly of the panel structure and an opposed side facing inwardly. Each of the opposed side faces is affixed to a respective side of the honeycomb core. The side panels are constructed essentially from material which, when not affixed to the honeycomb core, is non-structural and, when affixed to the honeycomb core, has a tensile strength sufficient to prevent compressive movement of the opposed side of the honeycomb core.

In accordance with another embodiment of this invention there is provided a panel structure comprising frame members defining the perimeter of the panel structure, the frame members having a first side facing outwardly of the panel structure and an opposed side facing inwardly, and a panel member extending between the frame members and engagable therewith. The panel member comprises an inner core having an open cell structure having a pair of opposed side faces, and a pair of opposed side panel members having a first side facing outwardly of the panel structure and an opposed side facing inwardly. Each of the opposed side faces is affixed to a respective side of the inner core. The side panels are constructed essentially from material which, when only one of the side panel members is affixed to the inner core, the only one of the side panel members will not prevent bending of that side of the inner core when a bending force is applied to opposed sides of the inner core and yet has a tensile strength sufficient to prevent compressive movement of the opposed side of the inner core when both of the panel members are affixed to the inner core.

In accordance with a further embodiment of the this invention there is provided a panel structure comprising top, bottom and side frame members defining the perimeter of the panel structure, the frame members having a first side facing outwardly of the panel structure and an opposed side facing inwardly, and a panel member extending between the frame members. The opposed sides of the frame members are configured to receive therein the panel member. The panel member comprises an inner honeycomb core of corrugated paper and a pair of opposed side panel members having a first side facing outwardly of the panel structure and an opposed side facing inwardly. Each of the opposed side faces is affixed to a respective side of the inner core. The side panels are constructed from a cardboard having a thickness less than about 0.05 inches.

Preferably, the honeycomb core has cell openings which are less than about 1.5 inches, more preferably less than about 1.0 inches and most preferably, less than about 0.5 inches. Further, the honeycomb core is preferably constructed from paper having a thickness of less than about 0.025 inches, more preferably less than about 0.015 inches and, most preferably less than about 0.01 inch.

Preferably, the opposed side panels are constructed from cellulosic material, such as planer (non-corrugated) cardboard or paper. However, other lightweight construction materials which can absorb tensile forces, such as thin foils or films (e.g. aluminum foil), might be utilized. If the side panel members are constructed from a cellulosic material, the exterior surface may be treated so as to be water resistant or water proof. For example, the exterior surface may be treated with a water resistant or waterproof compound or it may be covered with a water proof or water resistant material. In one embodiment, the exterior surface of the side panel members may be aluminized. Preferably, the opposed side panel members are constructed from planer cardboard and preferably having a thickness of less than about 0.05 inches, more preferably less than about 0.025 inches and, most preferably less than about 0.02 inches.

The panel structure of the instant invention is of a lightweight construction. In a preferred embodiment, the panel member may be constructed of paper and/or planer cardboard. Quite surprisingly, despite this construction, the panel member has sufficient structural integrity to be used as a office panel system without the need for internal reinforcement members provided on the interior of the panel member. For example, it has been determined that a panel structure constructed in accordance with the instant invention may accommodate a shelf which is capable of supporting up to 150 lbs. This is quite notable given the lightweight construction of the instant panel structure.

DESCRIPTION OF THE DRAWING FIGURES

These and other advantages of the instant invention will be more fully understood by the following description of a preferred embodiment, by way of example, in conjunction with the accompanying drawings:

FIG. 1 is a perspective view of a panel assembly according to the instant invention;

FIG. 2 is a partial cut away section of the panel shown in FIG. 1;

FIG. 3 is a partially exploded view of the panel shown in FIG. 1;

FIG. 4 is a cross-section along the line 4--4 of the panel of FIG. 1;

FIG. 5 is a cross-section along the line of 5--5 of the panel of FIG. 1;

FIG. 6 is a perspective view of a wall panel having a shelf positioned thereon;

FIG. 7 is a cross section along the line 7--7 of the panel and shelf of FIG. 6; and

FIG. 8 is an enlargement of a partial exploded view of Area A of FIG. 1.

DESCRIPTION OF PREFERRED EMBODIMENT

Referring to FIG. 1, there is shown a panel structure 10 comprising a panel member 12 and surrounded by frame members comprising a top frame member 14, a bottom frame member 16 and a pair of vertical frame members 18 (only one of which is shown in FIG. 1).

Frame members 14, 16 and 18 may be constructed from any material shown in the art and may be of any particular configuration which is adapted to engage panel member 12. Preferably, frame members 14, 16 and 18 are made from thin gauge metal (e.g. the frame members may have side walls which have a thickness of about 0.125 inches or less, preferably from about 0.030 to about 0.070 inches and more preferably from about 0.040 to about 0.060 inches). Preferably they are made from aluminium. Depending upon the configuration of the sheet metals, it may be preferably to manufacture them by extrusion.

Together, frame members 14, 16 and 18 define the exterior perimeter of panel structure 10 and define a perimeter extending around panel member 12. Frame members may inter-engage by any means known in the art. For example, top frame member 14 may inter-engage opposed vertical frame members 18 so as to define a continuous top and side perimeter around panel member 12. Similarly, bottom frame member 16 may inter-engage opposed vertical frame members 18 so as to define the remainder of the perimeter around panel member 12. Alternately, a connector means, such as bracket 20, may be used to connect the frame members together.

As shown in FIG. 3, top frame member 14 may be a longitudinally extending member having a generally I-beam shaped configuration in cross section. Accordingly, top frame member 14 may have a pair of opposed vertical faces 22 with a generally horizontal web member 24 extending therebetween. Web member 24 may extend from a position approximately mid-way along the interior surface of vertical faces 22. The lower portion of vertical faces 22 and the bottom surface of web member 24 define a generally U-shaped channel 26.

Preferably, top frame member 14 is configured to receive therein the edges of a fabric material which overlays panel member 12. Further, top frame member 14 may be configured to receive a top cap to provide a clean, decorative finish to panel structure 10. Accordingly, as shown in FIG. 5, vertical faces 22 may extend upwardly from web member 24 and define an internal surface 28. A plurality of horizontally extending protrusions (e.g. raised surfaces) may be provided on interior surface 28. Positioned inwardly from each of interior surfaces 28 is a generally vertically extending top cap securing arm 32. Top cap securing arms 32 have an interior surface 34 having a plurality of horizontally extending flange members 36 provided thereon. Horizontally extending channels 38 extends between vertical faces 22 and top cap securing arms 32.

Bottom frame member 16 may be of a similar construction to top frame member 14 and, preferably, is of an identical construction. If top and bottom frame members 14 and 16 are of an identical construction, then only one frame member need be manufactured and stocked as opposed to two.

Vertical frame members 18 may also be of any particular configuration provided they are adapted to engage panel member 12. As shown in FIGS. 3 and 4, vertical frame members 18 may be longitudinally (vertically) extending extrusions having vertically extending outer side faces 40 and vertically extending inner side faces 42. Inner and outer side faces 40 and 42 are connected together by first vertically extending web member 44 which is positioned approximately mid-way along the interior surface of outer side face 40. Each inner side face 42 extends between an inner end of first web member 44 and an outer end of second vertically extending web member 46.

Outer side faces 40 have an interior surface 48 having a plurality of protrusions 50 (e.g. raised surfaces). Each outer side face 40, inner side face 42 and first web member 44 define a vertically extending channel 52. Outer side faces 40 and web member 44 define a generally U-shaped channel for receiving panel member 12.

Second web member 46 may be configured to engage another panel structure 10 or a post by any means known in the art. For example, second web member 46 may be configured as disclosed in U.S. Pat. No. 5,491,943 (Vondrejs et al) which is incorporated herein by reference. Accordingly, second web member 46 may have a pair of connector arms 54 extending outwardly therefrom. Each connector arm 54 and web member 46 define a generally vertically extending channel 56. Further, second web member 46 may have a generally vertically extending recess 58 and a generally vertically extending protrusion 60.

Inner side face 42 has an interior surface 62. A longitudinally extending protrusion 64 is provided on interior surface 62 adjacent second web member 46. Each protrusion 64 and second web member 46 define a shallow channel 66.

Bracket 20 may be of any particular design to secure frame members 14, 16 and 18 together. In order to simplify the construction of frame structure 10, a single bracket 20 is used at each corner of panel structure 10. As shown in FIG. 3, bracket 20 has a first arm 70 and a second arm 72. First arm 70 is sized so as to be received in channel 66 in vertical frame member 18. Second arm members 74 is sized so as to be received on top of horizontal web member 24 between top cap securing arms 32 (see in particular FIG. 5). In order to secure