US3264649A - Interlocking panels - Google Patents

Description

1966 R. 5. WHITE 3,264,649

INTERLOCKING PANELS INVENTOR ROBERT 3. WHITE Kiwi-k ATTORNEY 2, 1966 v R. 5. WHITE 3,264,649

INTERLOCKING PANELS Filed July 16, 1962 2 Sheets-Sheet 2 FIG. 4 FIG.5 FIG.6

METALIZED PHENOLIC EPOXY MYLAR RESIN RESIN SHEET SHEET SHEET STEEL F] G 7 FRAMEWORK ANTENNA FACE AND REFLECTING FACE BOLTS AND WASHERS INVENTOR.

ROBERT 8. WHITE ATTORNEY United States Patent 3,264,649 INTERLOtJKiNG PANELS Robert S. White, Lake Hiawatha, Nah, assignor to Nicolet Industries, 1112., Florham Park, Ni, a corporation of Delaware Filed July 16, 1962, Ser. No. 2143349 7 Ciaims. 3!. 343915) My invention relates to an interlocking panel, a multiplicity of which are particularly adaptable for use in forming an antenna screen. A multiplicity of my improved interlocking panels may be used also for various other purposes, such as an insulating wall for buildings, etc.

The warning system, which is known as White Alice, for use by the US. Government, is in operation at present in Alaska and other Attic regions. The average installation, or station, of the warning system can handle 143 voice channels at one time through the use of radio telephone equipment specially developed for the warning system.

The average antenna screen presently used in an installation in the warning system is approximately 60 feet by 60 feet, Weighs about 100 tons, and the total weight of the supporting structure for such screen and other electronic gear is about 300 tons. The complete antenna, including the antenna screen, must withstand 150 mph. winds and a 6 inch ice load. Such antenna screens are made up of a series of steel panels which are caulked between the edges of each panel, which edges are double 45 bevels. The panels weigh about 410 pounds each. The panels of the antenna screen must be recaulked at least once a year, which consumes a considerable number of work days in a very cold atmosphere.

The presently used antenna screen is a parabolic curve, with each of the multiplicity of individual steel panels being curved horizontally and vertically so that the complete antenna screen will form a parabolic curve.

The weight factor of the material required to erect a present average installation, or station, including the panels, supporting structure, and other electronic gear, is most important, because such material quite frequently has to be transported into remote locations by helicopter.

After a considerable amount of research and development Work, I have determined that the substantial equivalent of the parabolic curve of the present antenna screen may be obtained by misalignment of the adjoining edges of individual plane panels, rather than by forming each panel horizontally and vertically so that the complete antenna screen will be a parabolc curve, Such misalignment, as I term it, may be accomplished by the use of simple wedge-shaped washers behind each panel where it is bolted to a supporting framework.

One object of my invention is to provide an interlocking plane panel of such construction that an antenna screen may be formed by a multiplicity of such plane individual panels which are misaligned to form a face which is the substantial equivalent of an antenna screen of parabolic curvature.

Another object of my invention is to provide an individual antenna panel which has a weight of only approximately twenty percent of the weight of the presently used panel, with the resultant antenna screen made therefrom meeting fully all the requirements of withstanding winds of 150 mph. and a 6 inch ice load.

Another object of my invention is to provide an interlocking panel which may be readily sealed with material which will withstand temperatures of l00 F. to +450 F.

Another object of my invention is to provide a panel r fifi lfi Ce Patented. August 2, 1%65 which when interlocked does not require that the joints line up in a straight line, and which panels may be staggeringly connected in the same manner as normally used in laying courses of building bricks for walls, houses, etc.

Another object of my invention is to provide a panel wherein either side of the panel may be used to form the substantial equivalent of the required parabolic curve of an antenna screen.

Another object of my invention is to provide a panel which may have the attaching holes for connection to the support members drilled at the site of erection.

Another object of my invention is to provide a panel of such relative light weight that it is possible to prebuild a plurality of such panels as subassemblies for the construction of the entire face of the antenna screen.

Another object of my invention is to provide a panel which may be assembled or disassembled without destroying the sealing efiiciency of the panels.

Another object of my invention is to provide a panel which may be made in various thicknesses depending upon the requirements for varying climatic conditions.

My invention includes the various novel features of construction and arrangement hereinafter more definitely specified.

In said drawings; FIG. 1 is a front elevation of one of my improved panels, with a portion of the outer covering removed to show the inner core, said panel being shown interlocked with a fragmentary portion of a second similar panel.

FIG. 2 is a vertical sectional view of the structure shown in FIG. 1, taken on the line 2-2 in FIG. 1.

FIG. 3 is a fragmentary vertical sectional view, partly in elevation and on a larger scale, showing the connecting means for the panels to a support member, and the means for misaligning the individual panels to produce the substantial equivalent of a parabolic curve.

FIG. 4 is a sectional view showing one form of my improved panel in which the outer housing for the honeycomb core l is provided with a metalized Mylar film 3a, Mylar being the Well-known commercial name of a polyester film.

FIG. 5 is a sectional view showing another form of my improved panel in which the outer housing is formed of a phenolic resin sheet 3b.

FIG. 6 is a sectional View of another form of my improved panel in which the outer housing is formed of an epoxy resin sheet 30.

FIG. 7 is a small scale, somewhat diagrammatic view showing an antenna screen mounted on a supporting steel framework and as used in an installation in a warning system.

Referring to said drawings; the inner core 1 of my improved panel is of honeycomb construction formed from corrugated glass fiber reinforced asbestos sheets. Such honeycomb construction is normally formed from a multiplicity of layers of such corrugated asbestos sheets which have an atfixed plane bottom sheet. The crests of the corrugations of the asbestos sheets are coated with adhesive and caused to adhere to the underside of the bottom sheet of the superimposed corrugated asbestos sheet, until a honeycomb core of the required height is produced. Of course, a honeycomb core of the desired width may be cut from larger honeycomb constructions.

The glass fiber reinforced asbestos honeycomb core 1 is encased, or covered, by an outer housing 2 of phenolic resin, or an epoxy resin, or a fiber glass laminate which has a highly durable, transparent, water repellent film of polyethylene tereph'thala-te resin (known commonly as Mylar), or aluminum sheet material which has an enamel coating on its outer surface, or surfaces. The Mylar polyester film is coated With a thin metallic film which l '13 can be vacuum metallized to the Mylar film. As best shown in FIG. 3, the housing 2 is formed of a front section 3 and rear section 4. The front section 3 is provided with a preipheral flange and the rear section 4 is provided with a corresponding peripheral flange '6.- The front and rear sections are assembled one within the" other so as to leave an open spacex8 between the flange 5 of the front section 3 and the flange 6 of the rear sec-- tion 4.

As best indicated in FIG. 3, the core 1, front section 3, and rear section 4 of the housing 2 are completely sealed to atmosphere by a sealant indicated at 10. As

would be obvious to anyone skilled in the art, when anantenna screen of the order of, say 60' X 60',thas beenv formed completely of a multiplicity of individual panels, such as indicated in FIG. 1, or of a multiplicity of subassemblies of such individual panels, the peripheral edges of the completed antenna screen :would be sealed with a sealant 10, such as indicated in FIG. -3.J l find it preferably to use a polyvinyl plastisol sealer, although, as, it is 'wellknown, other sealants having equivalent desirable characteristics may be used and which will withstandv temperatures of 'l00 P. to +450 F. As would be obvious to one skilled in the art;-the peripheral top, bottom, andside edges of the completed antenna screen, vor other structure, are sealed to atmosphere by a sealant.

When a multiplicity of my interlocking panels are used to form an antenna screen, the panels are rigidly secured to supporting structures, such as the U-channel 1'5, by

means of bolts 16. The bolts 16, with a washer 17 on the underside of the bolt head, extend through drilled openingsformed in the panels, through the openings in,

the wedge-shaped washers 20 positioned between .the outer face of therear section 4 and the web 21 of the U-channel 15, through matching openings formed in the web 21, andlock washers 23 and nuts 24 are tightly fastened on the inner screw threaded ends of the bolts 16.

The Wedgeshaped washers 20 areHof the well-known square configuration with a center opening for a bolt therethrough. Such type of beveledwashers, or wedgeshaped washers, are readily available on the commercial markets, and available in varying degrees of angularity of the cam face. With the use of such beveled washers 203 between the supporting frame member and the rear side of the interlocking panels, the plane panels maybe misaligned to form an antenna screen face which is the substantial equivalent of 'an antenna screen: of parabolic curvature.

Of course, if my interlocking panelsvare used to form ture; a multiplicity of interlocking substantially plane panels rigid-ly'secured to said supporting structure, each of said multiplicity of interlocking panels comprising a reinforced asbestos honeycomb core, a rigid outer hous ing completely encasing said core, said outer housing comprising a front section and, a rear section, both said front section and rearsection having integral inwardly turned peripheral flanges positioned one within the other in spaced relationship to provide a space in which the corresponding flanges of adjacentpanels are positioned in interlocking relationship with a sealant, a sealant in said space; and means positioned between the outer face of each rear sectionof each of said interlocking panels and said supporting structure to effect misalignment of each of said interlocking panels with respect to each other;

whereby, the outer face ,of the formed antenna screen I will be of a configuration which is the substantial l equivalent ofa parabolicscurve; and; whereby, each of said multiplicity. of interlocking panels form a unitary structure completely sealed to. atmosphere','and said multiplicity of interlockingpanels form a unitary structure completely sealed to atmosphere.

2.-An antenna screen comprising a supporting-structure; a multiplicity of interlocking substantially plane;

panels rigidly secured to said supporting structure, each of said multiplicityiof interlocking panels comprising a 7 glass fiber reinforced asbestos honeycomb core, a rigid plasticPouter housing completely encasing said core, said";

outer housing comprising a frontsection anda rear'section, bothzsaid front section and rear section having in tegral inwardly turned peripheral flanges positioned one within the other inspaced relationship to provide a space in which the corresponding flanges of adjacent panels are positionedin interlocking relationship with a sealant; t

a polyvinyl plastisol sealant in said space; and meansapositioned between tl16".0lll161 face of each rearsection of each of' said interlocking panels and said supporting stru'cture to effect misalignment of each of said interlocking panels with respect to each other; whereby, the outer face of the formed antenna screen will'be of'a configuration'which is the, substantial, equivalent of a parabolic,

curve; and whereby, each of said multiplicity of interlocking panel-s form a unitary structure completely sealed to atmosphere, and said multiplicity of interlocking panels form/a unitary structure :completely sealed to atmosphere.

3. An antenna screen comprising a supporting structure; a multiplicity of interlockingv plane panels rigidly.

secured to said supporting structure by bolt and nut means,

each ofsaid multiplicity of. interlocking :plane panels comprising a glass fiber, reinforced asbestos honeycomb,

core, a rigid plastic? outer :housingv completely encasing saidcore, said outer. housing comprising ,a front section and a rear section, 'bothsaidfront section and rear section having integralinwardly turned peripheralfla'nges -positioned one within the other in spaced relationship to provide a space inwhich the corresponding flanges of adjacent panels are positioned in interlocking relationshipwith a sealant; a polyvinylplastisol sealant in said space;

and wedge shapedwasher means positioned on;said bolt means between the outer-face of each reansection of, each of said interlocking panels and said supportingstructure;

to effect misalignment of each of said interlocking plane panels with respectto each other; whereby,'the .outer face of the formed antenna screen, will be of a configurationwhichis the substantial equivalent of a parabolic curve; and whereby, each of saidmultiplicity of interlocking: panels form a unitary structure completely'sealedto atmosphere,yvand said multiplicity of interlocking panels form a unitary structure completely sealed to atmosphere.

4.2A structure as in claim 3,-whereinsaid outer hous-v ing is formed of'phenolic resin. t

5.- A structure as in claim 3, wherein said outerhousing is formed of an epoxy resin.

6. A structure as in claim 3, wherein said outer housing is formed ofa fiber-glass laminate which has been coated with metalized Mylar..

7. An antenna screen comprising a sup-porting struca ture; a multiplicity of. interlocking plane panels rigidly secured to said supporting ,structurebybolt and nut; means, each of said multiplicity of interlocking-plane;

panels comprising a glass fiber reinforced asbestos honeycomb core, .a rigid metal outer housing, completely encasing said core, said outer housing comprising a front section and a rearsection, both said front sectionsand rear section having integral inwardly turned peripheralflanges positionedone within the other in spaced relationship to providea space in which the-corresponding flanges of adjacent panels are POSltlOllCd,lllzifltCliOCklIlg:IClallOIL- ship with a sealant; a polyvinyl plastisol sealant in said space; and beveled-faced means positioned on said bolt means between the outer face of each rear section of each of said interlocking panels and said supporting structure to effect misalignment of each of said interlocking plane panels with respect to each other; whereby, the outer face of the formed antenna screen will be of a configuration which is the substantial equivalent of a parabolic curve; and whereby, each of said multiplicity of interlocking panels form a unitary structure completely sealed to atmosphere, and said multiplicity of interlocking panels form a unitary structure completely sealed to atmosphere.

References Cited by the Examiner UNITED STATES PATENTS Gehnnrich 189-36 Parkes 189-34 Creulich 52-578 Giuliani 343-912 Kreitzberg 343-916 X Holland et al. 343-915 Tuttle 189-36 McIlroy et al. 343-915 Banche et al 343-915 ELI LIEBERMAN, Primary Examiner.

Claims (1)

1. AN ANTENNA SCREEN COMPRISING A SUPPORTING STRUCTURE; A MULTIPLICITY OF INTERLOCKING SUBSTANTIALLY PLANE PANELS RIGIDLY SECURED TO SAID SUPPORTING STRUCTURE, EACH OF SAID MULTIPLICITY OF INTERLOCKING PANELS COMPRISING A REINFORCED ASBESTOS HONEYCOMB CORE, A RIGID OUTER HOUSING COMPLETELY ENCASING SAID CORE, SAID OUTER HOUSING COMPRISING A FRONT SECTION AND A REAR SECTION, BOTH SAID FRONT SECTION AND REAR SECTION HAVING INTEGRAL INWARDLY TURNED PERIPHERAL FLANGES POSITIONED ONE WITHIN THE OTHER IN SPACED RELATIONSHIP TO PROVIDE A SPACE IN WHICH THE CORRESPONDING FLANGES OF ADJACENT PANELS ARE POSITIONED IN INTERLOCKING RELATIONSHIP WITH A SEALANT, A SEALANT IN SAID SPACE; AND MEANS POSITIONED BETWEEN THE OUTER FACE OF EACH REAR SECTION OF EACH OF SAID INTERLOCKING PANELS AND SAID SUPPORTING STRUCTURE TO EFFECT MISALIGNMENT OF EACH OF SAID INTERLOCKING PANELS WITH RESPECT TO EACH OTHER; WHEREBY, THE OUTER FACE OF THE FORMED ANTENNA SCREEN WILL BE OF A CONFIGURATION WHICH IS THE SUBSTANTIAL EQUIVALENT OF A PARABOLIC CURVE; AND WHEREBY, EACH OF SAID MULTIPLICITY OF INTERLOCKING PANELS FORM A UNITARY STRUCTURE COMPLETELY SEALED TO ATMOSPHERE, AND SAID MULTIPLICITY OF INTERLOCKING PANELS FORM A UNITARY STRUCTURE COMPLETELY SEALED TO ATMOSPHERE.

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