US3066059A - Structural elements - Google Patents

Structural elements Download PDF

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US3066059A
US3066059A US758731A US75873158A US3066059A US 3066059 A US3066059 A US 3066059A US 758731 A US758731 A US 758731A US 75873158 A US75873158 A US 75873158A US 3066059 A US3066059 A US 3066059A
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cells
sheets
dimples
pair
cellular
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Adie George Mountford
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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
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D24/00—Producing articles with hollow walls
    • B29D24/002—Producing articles with hollow walls formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled
    • 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
    • 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
    • E04C2/32—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 formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material
    • 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
    • E04C2/32—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 formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material
    • E04C2/326—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 formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material with corrugations, incisions or reliefs in more than one direction of the element
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0012—Combinations of extrusion moulding with other shaping operations combined with shaping by internal pressure generated in the material, e.g. foaming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0013—Extrusion moulding in several steps, i.e. components merging outside the die
    • B29C48/0014—Extrusion moulding in several steps, i.e. components merging outside the die producing flat articles having components brought in contact outside the extrusion die
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0018—Combinations of extrusion moulding with other shaping operations combined with shaping by orienting, stretching or shrinking, e.g. film blowing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0021—Combinations of extrusion moulding with other shaping operations combined with joining, lining or laminating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B29C48/08—Flat, e.g. panels flexible, e.g. films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/13—Articles with a cross-section varying in the longitudinal direction, e.g. corrugated pipes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12—Thermoplastic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/722—Decorative or ornamental articles
    • 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
    • E04C2002/3472—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
    • 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
    • E04C2002/3494—Apparatus for making 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
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00—Stock material or miscellaneous articles
    • Y10S428/92—Fire or heat protection feature
    • Y10S428/921—Fire or flameproofing
    • 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.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24496—Foamed or cellular component
    • 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.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24521—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness with component conforming to contour of nonplanar surface
    • Y10T428/24545—Containing metal or metal compound
    • 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.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24595—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness and varying density

Definitions

  • cellular materials are attractive for various reasons including their lightness. Generally speaking, however, cellular materials are not suitable for use by themselves but have to be faced with a material which is more resistant to concentrated loads, and they are most commonly used as the filling material between two boards of substantial rigidity and tensile and compressive strengths.
  • Cellular materials by cellular material is meant a material which throughout its length and breadth comprises a series of regular closed cells
  • cellular material can be made by the juxtaposition of cell forming elements but are more commonly made by a casting or moulding process designed to leave pores or voids in the starting material.
  • it has been usual to use cells all of the same size; while in the latter case, it is found difficult t control the size of the cells with any great accuracy, and impossible to exercise any substantial degree of control over the distribution of the cells.
  • the invention includes within its scope a slab, panel, plank or the like, of cellular material in which the density of the material is graded so as to be a maximum in the neighbourhood of one or both of its faces, and a minimum in the neighbourhood of the opposite face, or the median plane as the case may be.
  • a slab, panel, plank or the like of cellular material in which the density of the material is graded so as to be a maximum in the neighbourhood of one or both of its faces, and a minimum in the neighbourhood of the opposite face, or the median plane as the case may be.
  • the facing element need not, however, be a board such as has usually been used but is preferably in the nature of a skim that is to say a thin sheet having little inherent rigidity but which may have been rigidied by the provision of thin ribs which project from one of its faces and serve as a means for keying the skin to the slab.
  • the variation in density of the cellular material which is characteristic of the invention can be contrived in various ways.
  • the slab can be made up of layers or slices having cells of different sizes, of different shapes. or of different wall thicknesses, or of different materials.
  • the density would vary smoothly with increasing distance from one or both faces but, in practice, it is sufficient that it vary step-by-step.
  • the invention extends also to a novel form of cellular material formed by the juxtaposition of thin sheets of mouldable material, such as a thermoplastic, having dimples or cups formed in them, the open sides of the dimples being brought opposite each other to provide the cells.
  • mouldable material such as a thermoplastic
  • the invention further includes a plant for the fabrication of such a cellular material.
  • FIGURES l and 2 are explanatory diagrams
  • FIGURE 3 shows diagrammatically a plant for fabricating a cellular material
  • FIGURE 4 shows a dimpied sheet produced at an intermediate stage by the plant of FIGURE 3;
  • FIGURE 5 is a section taken on the line V-V in FIGURE 4;
  • FIGURE 6 shows one use of a cellular element in accordance with the invention.
  • FIGURE 7 shows an element containing cells formed by truncated cones.
  • FIGURE 1 In the diagram of FIGURE 1 is shown a mass 10 having throughout its length and breadth a series of symmetrical closed cells bounded by ⁇ a skin 12 of non-cellular material which provides the cellular mass with a substantially improved resistance to penetration under the effect of la concentrated compressive load, such as is indicated at
  • the force F which is applied over a very small area becomes diffused over a much larger area as it travels through the mass, as indicated in the drawing. Consequently, with increasing distance from the skin 12, the strength which the cellular material must have in order to resist the force F decreases.
  • the density of the cellular material can therefore be made to decrease away from the skin 12. Here, that is done by gradually increasing the size of the cells 14.
  • a slab such as is shown in FIGURE l can be used where the face remote from the skin 12 is protected as, for example, when the slab is used as a iloor or wall covering.
  • a double-sided slab can be used as shown in FIGURE 2 in which there is a skin 12 on each side, and the density of the cellular material decreases away from each skin so as to be a minimum in the neighbourhood of the median plane of the slab.
  • foaming The most common method of giving materials such as rubber and plastics a cellular structure of closed cells is the so-called foaming
  • foaming The methods of foaming in use to-day do not, however, allow the specific gravity of the end product to be predicted with any degree of accuracy.
  • Foamed products can, however, be used in accordance with the invention if the precaution is taken of producing blocks of distinctly different nominal densities (for example, in the ratio 1:224), cutting the blocks into thin slices and grading the slices by weight before assembling them to form the desired slab.
  • the slices must, of course, be caused to adhere strongly to each other, for example, by interleaving them with adhesive cellulose or like strips.
  • FIGURE 3 shows a plant which can be used to make a cellular material in accordance with the invention from material in roll form.
  • thermo-plastic material such as polyvinyl chlor1 e.
  • rolls are arranged in groups of three, such as A1, A2, A3; A4, A5, A6, etc., separated by the rolls A4, A8, etc.
  • the foils F1 and F3 from the extreme rolls in the first group are passed through pairs of rolls B1, B3 which form them to the shape shown in FIGURES 4 and 5, that is to say put dimples or cups 16 into them.
  • the foil F2 from the centre roll is not dimpled but passes between a pair of sprays S1 which spray an adhesive on to both its sides and the facing sides of the dimpled foils.
  • the three foils F1, F2, F3 then pass through a pressing roller assembly Cl which causes them to be joined together as a single sheet having substantiallyspherical cells of a size determined by the dimpling rolls B1, B3.
  • the foils from the rolls A5, A6, A7 are subjected to the same process but are providedwith larger cells; the foils from the rolls A9, A10, A11, are also similarly treated but are provided with still larger cells.
  • the cellular sheets D so formed are fed onwardly between a further pair of presser roll assemblies C2. They are interleaved with foils F4, Fg, F12 which are provided with adhesive from the sprays S2.
  • skins E corresponding to the skins 12 of FIG URE 2, and of somewhat greater thickness than the foils, are fed to the presser roll assemblies C2 after having been coated with adhesive.
  • the foils and the skins are thus pressed into a cellular slab or block of indefinite length having a regular series of symmetrical closed cells which can be cut as desired and the density of which decreases with increasing distance from the outer skins.
  • the plant required is of a very simple nature and formed of parts which are readily available as they are akin to those used in paper-making machines.
  • thermoplastic foils When using thermoplastic foils, they can be welded together instead of being stuck, the sprays S1 and S2 being replaced by radiant heaters.
  • the dimples formed by the rolls B1 etc. need not be hemispherical. As already indicated, they could be truncated cones or pyramids.
  • the foils can be very thin. They can, for example, be as thin as say 0.006 inch. Their thickness will depend on the material and in general will not exceed -,O inch.
  • the outer skins can also be quite thin, for example, up to about 1,432 inch.
  • the method just described lends itself to the use of foils of different materials or thicknesses, and to the provision of as many layers or slices -as are desired. Also, the inter-cellular spaces and/or cells may be filled with any desired hardening, fire-proofing or other material.
  • Cellular materials in accordance with the invention can be used for a wide variety of purposes.
  • An obvious use is partitioning.
  • Another is as a facing material, for heat or sound insulation or any other purpose, in which case, one of the outer skins can with advantage be omitted s as to provide a non-plane face which may prove a good key for plaster cement and the like.
  • a slab comprising a cellular mass 10 andprotective skins 12 to one of which has been applied a dimpled foil of the kind shown in FIGURES 4 and 5 t with the dimples opening upwardly.
  • the dimples are covered by a foil which can be stripped off as shown.
  • concrete or plaster 22 can be laid and supported by the slab acting as a shutter or form which, however, remains attached to the cast mass.
  • the upper skin 12 can be omitted.
  • the dimpled foil i8 can be replaced by a ribbed skin of the kind with which my British patent application Nos. 12923/56 and 5484/57 are concerned, the ribs projecting away from the cellular slab.
  • the invention lends itself very well to the use of plastics, and particularly thermoplastics, it olers a wide choice of material which depends on the ultimate use of the nal product, and will be governed by such G5 tial considerations as toughness; ability of surface to withstand scratching; and to provide a decorative effect; high tensile and compressive strength; ability to resist impact and sharp point loads while being of light weight and of a desired thickness; non-inammability; resistance to melting and deformation at high temperature; resistance to attack by inescts, weather and industrial fumes; high strength per unit of weight; and so on.
  • a building element formed of at least three pairs ofjuxtaposed thin exible sheets of mouldable material, cachY sheet of a pair havingra series of regular shaped dimplesformed in it, the dimples being arranged in a regular pattern with flat portions between the dimples, the open sides of the dimples in the sheets of a pair being disposed opposite each other to provide closed cells, the cells formed byy one pair of sheets varying in size from those of the others and the pairs being arranged so that the diameters of the cells are graduated in size progressively from vone of its faces to the other, and foils disposed between each pair of cell sheets.
  • a building element according to claim 1 in which the element is faced on at least one side with a skin of a non-cellular material having a substantial lresistance to penetration by concentrated compressive loads.
  • a building element formed of at least five pairs of juxtaposed thin flexible sheets of mouldable material, each sheet of a pair having a series of regular shaped dimples formed in it, the dimples being arranged in a regular pattern with flat portions between the dimples, the open sides of the dimples in the sheets of a pair being disposed opposite each other to provide closed cells, the cells formed by at least three pairs of sheets varying in size from each other and the pairs of sheets being arranged so that the diameters of the cells are graduated in size progressively from a minimum in the vicinity of one of its faces to a maximum in the vicinity of its median plane, and foils disposed between each pair of cell sheets.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
US758731A 1957-09-03 1958-09-03 Structural elements Expired - Lifetime US3066059A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB27840/57A GB887001A (en) 1957-09-03 1957-09-03 Improvements in and relating to laminated structural elements and apparatus for making such elements

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US (1) US3066059A (fr)
BE (1) BE570825A (fr)
FR (1) FR1213565A (fr)
GB (1) GB887001A (fr)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3248464A (en) * 1962-08-22 1966-04-26 Dow Chemical Co Method and apparatus for making large celled material
US3640831A (en) * 1969-12-15 1972-02-08 Protective Pads Inc Protective body pad
US5116443A (en) * 1988-06-17 1992-05-26 Envirotech Corporation Clarifier apparatus and methods with 3D arrays
EP0473372A3 (en) * 1990-08-31 1992-10-21 General Electric Company Composite element
DE4208812A1 (de) * 1992-03-19 1993-09-23 Tubus Bauer Gmbh Vorrichtung und verfahren zum herstellen einer leichtbauplatte sowie danach hergestellte leichtbauplatte
US20120085487A1 (en) * 2010-10-11 2012-04-12 Bradford Company Multi-Layered Product Having Dimpled Interior and Method of Making Same
US10197125B2 (en) 2010-12-10 2019-02-05 Skydex Technologies, Inc. Interdigitated cellular cushioning
USD1013214S1 (en) * 2021-01-12 2024-01-30 Durlum Group Gmbh Cladding element for building

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4702048A (en) * 1984-04-06 1987-10-27 Paul Millman Bubble relief form for concrete
GB2182703B (en) * 1985-09-30 1989-12-28 George William Hunter Improvements relating to structural sheet material
CH695701A5 (de) * 2001-06-05 2006-07-31 Empa Leichtbau-Verbundelement, sein Herstellungsverfahren und seine Verwendung.

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1116185A (en) * 1914-03-16 1914-11-03 Gen Fireproofing Co Building material.
US1802880A (en) * 1930-03-31 1931-04-28 Willard J Mason Method of manufacture of laminated fibrous structures
US2129488A (en) * 1934-03-30 1938-09-06 Inland Container Corp Indented paperboard article
US2268049A (en) * 1936-02-12 1941-12-30 Airfilm Corp Method of making composite material
GB551733A (en) * 1941-10-27 1943-03-08 John Leon Menzies Stone Banks Improvements in cellular materials for structural or other purposes
US2333343A (en) * 1937-04-22 1943-11-02 Armzen Company Method of making structural materials
US2759523A (en) * 1953-10-02 1956-08-21 Corro Ltd Method and machine for making triple wall corrugated paper board
US2855021A (en) * 1948-10-01 1958-10-07 Bayer Ag Process for producing plates, sheels and shaped elements
US3003599A (en) * 1955-03-02 1961-10-10 Ind Dev Co Construction elements

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1116185A (en) * 1914-03-16 1914-11-03 Gen Fireproofing Co Building material.
US1802880A (en) * 1930-03-31 1931-04-28 Willard J Mason Method of manufacture of laminated fibrous structures
US2129488A (en) * 1934-03-30 1938-09-06 Inland Container Corp Indented paperboard article
US2268049A (en) * 1936-02-12 1941-12-30 Airfilm Corp Method of making composite material
US2333343A (en) * 1937-04-22 1943-11-02 Armzen Company Method of making structural materials
GB551733A (en) * 1941-10-27 1943-03-08 John Leon Menzies Stone Banks Improvements in cellular materials for structural or other purposes
US2855021A (en) * 1948-10-01 1958-10-07 Bayer Ag Process for producing plates, sheels and shaped elements
US2759523A (en) * 1953-10-02 1956-08-21 Corro Ltd Method and machine for making triple wall corrugated paper board
US3003599A (en) * 1955-03-02 1961-10-10 Ind Dev Co Construction elements

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3248464A (en) * 1962-08-22 1966-04-26 Dow Chemical Co Method and apparatus for making large celled material
US3640831A (en) * 1969-12-15 1972-02-08 Protective Pads Inc Protective body pad
US5116443A (en) * 1988-06-17 1992-05-26 Envirotech Corporation Clarifier apparatus and methods with 3D arrays
EP0473372A3 (en) * 1990-08-31 1992-10-21 General Electric Company Composite element
DE4208812A1 (de) * 1992-03-19 1993-09-23 Tubus Bauer Gmbh Vorrichtung und verfahren zum herstellen einer leichtbauplatte sowie danach hergestellte leichtbauplatte
US20120085487A1 (en) * 2010-10-11 2012-04-12 Bradford Company Multi-Layered Product Having Dimpled Interior and Method of Making Same
US10197125B2 (en) 2010-12-10 2019-02-05 Skydex Technologies, Inc. Interdigitated cellular cushioning
USD1013214S1 (en) * 2021-01-12 2024-01-30 Durlum Group Gmbh Cladding element for building

Also Published As

Publication number Publication date
BE570825A (fr) 1900-01-01
FR1213565A (fr) 1960-04-01
GB887001A (en) 1962-01-10

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