WO2000034598A1 - Fiberglass partition and method of making same - Google Patents

Fiberglass partition and method of making same Download PDF

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Publication number
WO2000034598A1
WO2000034598A1 PCT/US1999/029061 US9929061W WO0034598A1 WO 2000034598 A1 WO2000034598 A1 WO 2000034598A1 US 9929061 W US9929061 W US 9929061W WO 0034598 A1 WO0034598 A1 WO 0034598A1
Authority
WO
WIPO (PCT)
Prior art keywords
panel
fiberglass
core
molding
composite panel
Prior art date
Application number
PCT/US1999/029061
Other languages
French (fr)
Inventor
Paul Vassallo
Frank Catena
Original Assignee
Vassallo Precast Manufacturing Corp.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Vassallo Precast Manufacturing Corp. filed Critical Vassallo Precast Manufacturing Corp.
Priority to CA002318856A priority Critical patent/CA2318856A1/en
Publication of WO2000034598A1 publication Critical patent/WO2000034598A1/en

Links

Classifications

    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • 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
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-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
    • E04C2/34—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
    • E04C2/36—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 transversely-placed strip material, e.g. honeycomb panels
    • E04C2/365—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 transversely-placed strip material, e.g. honeycomb panels by honeycomb structures
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/024—Honeycomb
    • 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
    • B32B2419/00—Buildings or parts thereof

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

A toilet or shower stall partition (10) having a honeycomb core (11) with a molding (12) surrounding the entire perimeter thereof for finishing off the partition (10). The partition (10) is of a sandwich type wherein the sandwich has a honeycomb core (11) having a fiberglass panel (13) on either side thereof and on the other side of each fiberglass panel (13) is a thin layer of acrylic gelcoat (14). The honeycomb core (11) is saturated with a resin before it is affixed to the side of the fiberglass panel (13) not having the acrylic gelcoat finish (14).

Description

FIBERGLASS PARTITION AND METHOD OF MAKING SAME
BACKGROUND OF INVENTION
Field of the Invention
The present invention generally involves the field of technology pertaining to a fiberglass reinforced composite panel of a sandwich or core construction type used as a component in the construction or renovation of shower partition applications or toilet stall partitions or the like. Also disclosed is a method for MAKING same.
The finished partition which forms the subject matter of this invention is finished on two sides, has a honeycomb core, and a molding surrounding the perimeter thereof.
In general terms, the partition or panel comprises two tempered glass panels used as molds. These glass molds are first waxed with any well known mold release wax which is then sprayed with gelcoat. After the gelcoat has sufficiently dried, a layer of fiberglass, with resin, is inserted into the mold and left to dry. The same is done for a second panel. Subsequently, when the panels have cured, they are extracted from the tempered glass mold.
With the finished side of one of the panels facing downwardly, a honeycomb, saturated with resin, is placed on the reverse or top or unfinished side of the panel. The second fiberglass panel is then placed over the honeycomb with the second panel's finished side facing up. A vacuum bag procedure is then utilized to produce a flat panel which is then left to dry again.
This finished panel may then be trimmed to the desired size leaving a clean flat edge into which molding is inserted completely surrounding the edge to thereby enclose the panel. Giving consideration to durability, maintenance and product life, the end product of this invention is superior to standard painted steel designs
Description of the Prior Art
While a search of the prior art disclosed numerous patents pertaining to partition panels, only three of those references are deemed to be particularly relevant Those three are U S Patent Number 5,336 354 to Looi, et al , 5,545,446 also to Looi, et al , and, 5,643,652 to Maurer, et al
Both patents to Looi, et al relate to a transparent or translucent bath or shower panel comprising two layers of resin - impregnated fiberglass and a non-woven tissue arranged between the fiberglass layers In the instant invention, there is disposed, between two fiberglass layers, a honeycomb or foam core This is completely absent from the Looi, et al patent which depends upon a non-woven tissue between the fiberglass layers
The other Looi patent, 5,545,446 is seen to be quite similar in structure to the Looi patent mentioned above and the same differences exist as between it and the instant invention, that is, the honeycomb or foam core between two fiberglass layers as indicated above
The Maurer, et al patent, 5,643,652 is also a composite panel for toilet and shower partition systems but which employs a core sheet of cellular material and two sheets of solid surfacing material and a bonding agent for bonding the solid surfacing material sheets to opposite surfaces of the core sheet Such is absent from the instant invention
Also differentiating the instant invention from the three foregoing prior art references is the absence, in those references, of a serrated or a sawtooth molding which extends completely around the finished panel and bites into the honeycomb or foam core and serves as a molding to provide a finished look to the partition
This molding may be made of aluminum or other suitable materials and extends completely from top to bottom and across the top and bottom of the panel and extends to a depth of approximately one-half inch into the honeycomb core.
None of the references taken by themselves nor combined with each other would appear to disclose the instant invention.
SUMMARY OF THE INVENTION
According to the present invention there is provided a "sandwich" panel or partition suitable for use as toilet stall or shower stall partition which is finished on both sides and wherein a molding made of aluminum or other suitable material completely surrounds the perimeter of the panel on all four sides; that is, on the two horizontal ends and the two vertical ends of the partition. The "sandwich" comprises a honeycomb core which also can be formed from foam material or any other suitable material. On either side, that is on both sides, of this honeycomb or foam core is a fiberglass panel and on the opposite sides of the fiberglass panel, that is, the side of each panel not contacting the honeycomb or foam core, is a thin layer of acrylic gelcoat. Further, the honeycomb core of the "sandwich" is saturated with a resin before it is affixed to the side of the fiberglass panel not having the acrylic gelcoat finish.
The finished product then receives a strip of molding, preferably made of aluminum but may be made of any other suitable material, which extends completely around the perimeter and which extends into the panel and digs into the honeycomb or foam core, by means of sawtooth serrations extending from the molding.
It is, therefore, an object of the present invention to provide a novel, lightweight, structurally sound panel which serves as a partition in toilet and shower stalls
It is another object of the invention to provide such a panel which is of sandwich construction.
It is a further object of the invention to provide such a panel wherein the sandwich type panel has a central core of fiber glass. It is still a further object of the invention to provide such a panel wherein the panel is finished on two sides with a honeycomb core and a molding surrounding the perimeter thereof.
It is still a further object of the invention wherein the sandwich construction comprises a honeycomb or foam core, a sheet of fiberglass on each side of the honeycomb or foam core, and a thin coat of acrylic gel disposed on the other side of each fiberglass panel.
These and further objects, features, and advantages of the invention shall become apparent from the following detailed description of a preferred embodiment thereof when taken in conjunction with the drawings wherein like reference characters refer to corresponding parts in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a side view of a panel of the instant invention partially cut away to show the honeycomb core and further showing the molding surrounding the four sides of the panel.
Figure 2 is an end view of Figure 1 showing the molding.
Figure 3 is a sectional view of the panel taken on line 3-3 of Figure 1 and clearly showing the honeycomb core and the molding across the top and bottom of the panel.
Figure 4 is an exploded view showing, from top to bottom, a thin gelcoat, fiberglass panel, honeycomb or foam core, and fiberglass panel and also showing the molding surrounding the lower fiberglass panel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A fiberglass panel that may serve as a toilet stall or shower stall partition having a honeycomb or foam core and a molding surrounding the entire perimeter of the panel and a method of MAKING same will now be described with reference to Figures 1-4 of the drawings
The fiberglass reinforced composite panel is shown in Figure 1 generally at 10 having a small section cut away to show a honeycomb core at 11 and a molding shown in Figures 1 and 2 at 12 which surrounds all four sides of the perimeter of panel 10 The molding may be of aluminum or any other suitable material and, as best seen in Figure 4, has sawtooth serrations projecting inwardly and which dig into honeycomb core 10 to keep it in place
Disposed on both sides of honeycomb core 11 in a resin impregnated fiberglass panel such as seen at 13 in Figure 4 In turn, resin impregnated panels 13 are each coated with a thin gelcoat spray on the surface opposite that surface of the panel 13 which does not contact the surfaces of honeycomb core 11 such as shown as 14 and best seen in Figures 3 and 4
The finished panel or partition therefore comprises an inner honeycomb core having a resin impregnated fiberglass panel on each face thereof and an acrylic gelcoat on the opposite surface of each of the resin impregnated fiberglass panels This "sandwich" comprising the five layers heretofore mentioned are then surrounded on all four sides by a molding which has sawtooth serrations which dig into the honeycomb core thereby finishing off the panel
A method of producing such fiberglass reinforced composite panel will now be described
First, two tempered glass panels are used as molds It should be obvious that any other suitable material may be used These glass molds are then waxed with a mold release wax and then sprayed with gelcoat 14 After the gelcoat has dried a layer of fiberglass with resin is rolled out into each of the molds where it is left until dried After these fiberglass panels have cured they are separated from the molds The finished side, that is, the side of the resin impregnated panel that contains the resin is placed face down and the honeycomb core saturated with resin is then placed on top of the unfinished or unresin impregnated side of such fiberglass panel. The second of such resin impregnated fiberglass panels is then disposed on top of the honeycomb core with the finished side facing up. A vacuum bag procedure is then performed to produce a flat panel. This sandwich construction is again left to dry and the finished panel is then trimmed to leave a clean flat edge to accept the molding which completely surrounds all four sides of the panel to enclose it. This finished partition is a fiberglass reinforced composite panel of a "sandwich" or "core" type basically comprising two fiberglass sides with a core of honeycomb disposed there between and wherein the honeycomb can also be foam.
Though the invention has been described and illustrated with reference to a preferred embodiment thereof, those skilled in the art will appreciate the various changes and modifications in shape, size, composition, and arrangement of parts may be resorted to without departing from the spirit of the invention or scope of the subjoined Claims.

Claims

What is Claimed:
1. A composite panel to be used as a partition between toilet or shower stalls or the like comprising:
(a) a core;
(b) a fiberglass panel disposed on both side of said core; and,
(c) a gelcoat spray disposed on surface of each of said fiberglass panels opposite the surface of said fiberglass not in contact with a surface of said core.
2. The composite panel of Claim 1 wherein said core is honeycomb.
3. The composite panel of Claim 1 wherein said core is foam.
4. The composite panel of Claim 1 wherein said fiberglass panels are resin impregnated.
5. The composite panel of Claim 1 wherein a molding surrounds said panel, at the perimeter thereof, for enclosing the said panel, and wherein said molding has sawtooth serrations projecting inwardly into said core for holding said molding in place.
6. A composite panel to be used as a partition between toilet or shower stalls or the like comprising:
(a) a honeycomb core;
(b) resin impregnated panels disposed on both sides of said honeycomb core;
(c) a gelcoat spray disposed on a surface of each of said fiberglass panels opposite that surface of said fiberglass panel not in contact with a surface of said core;
(d) a molding surrounding said panel, at the perimeter thereof, for enclosing said panel, and, wherein said molding has sawtooth serrations projection inwardly into said core for holding said molding in place.
7. A method of MAKING a composite panel to be used as a partition between toilet or shower stalls or the like in which the method comprises the steps of:
(a) waxing molds with a mold release wax;
(b) spraying said waxed molds with gelcoat;
(c) allowing said gelcoat to dry;
(d) rolling out a layer of resin impregnated fiberglass and placing said fiberglass into said molds;
(e) allowing said fiberglass to dry;
(f) separating said fiberglass panels from said molds
(g) placing a honeycomb core, saturated with resin, on one side of a fiberglass panel;
(h) placing a second resin impregnated fiberglass panel on top of said honeycomb core with a finished side facing up;
(i) applying a vacuum to said composite panel to produce a flat panel;
(j) allowing said composite panel to dry; (k) trimming said composite panel to leave a clean flat edge; and
(I) placing a molding around the perimeter of said composite panel to enclose it.
PCT/US1999/029061 1998-12-07 1999-12-07 Fiberglass partition and method of making same WO2000034598A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA002318856A CA2318856A1 (en) 1998-12-07 1999-12-07 Fiberglass partition and method of making same

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US20707498A 1998-12-07 1998-12-07
US09/207,074 1998-12-07

Publications (1)

Publication Number Publication Date
WO2000034598A1 true WO2000034598A1 (en) 2000-06-15

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WO (1) WO2000034598A1 (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL1027257C2 (en) * 2004-10-15 2006-04-19 Henk Slebos Construction panel for forming a wall of a cryogenic tank.
EP1698738A3 (en) * 2005-03-04 2007-11-14 REHAU AG + Co Lightweight building panel and method of production
FR3050138A1 (en) * 2016-04-18 2017-10-20 Groupe Renouveau Habitat Int Grhi MULTILAYER PANEL

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5328744A (en) * 1990-10-09 1994-07-12 E. I. Du Pont De Nemours And Company Panel having a core with thermoplastic resin facings
US5336354A (en) * 1987-04-24 1994-08-09 Looi Hon Y Method of manufacturing a laminated panel
US5545446A (en) * 1989-10-24 1996-08-13 Looi; Hon Y. Bath or shower panel
US5643652A (en) * 1994-09-28 1997-07-01 Centura Solid Surfacing, Inc. Composite panel for toilet and shower partitions
US5894044A (en) * 1997-04-21 1999-04-13 The Procter & Gamble Company Honeycomb structure and method of making
US5895701A (en) * 1997-02-21 1999-04-20 Dan-Pal Extruded panel unit for constructional purposes
US5914175A (en) * 1997-08-25 1999-06-22 Duraframe Window Shutter Systems Inc. Composite panel and method
US5960606A (en) * 1997-02-28 1999-10-05 Dlubak; Francis Charles Penetration resistant window

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5336354A (en) * 1987-04-24 1994-08-09 Looi Hon Y Method of manufacturing a laminated panel
US5545446A (en) * 1989-10-24 1996-08-13 Looi; Hon Y. Bath or shower panel
US5328744A (en) * 1990-10-09 1994-07-12 E. I. Du Pont De Nemours And Company Panel having a core with thermoplastic resin facings
US5643652A (en) * 1994-09-28 1997-07-01 Centura Solid Surfacing, Inc. Composite panel for toilet and shower partitions
US5895701A (en) * 1997-02-21 1999-04-20 Dan-Pal Extruded panel unit for constructional purposes
US5960606A (en) * 1997-02-28 1999-10-05 Dlubak; Francis Charles Penetration resistant window
US5894044A (en) * 1997-04-21 1999-04-13 The Procter & Gamble Company Honeycomb structure and method of making
US5914175A (en) * 1997-08-25 1999-06-22 Duraframe Window Shutter Systems Inc. Composite panel and method

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL1027257C2 (en) * 2004-10-15 2006-04-19 Henk Slebos Construction panel for forming a wall of a cryogenic tank.
WO2006041294A1 (en) * 2004-10-15 2006-04-20 Henk Slebos Construction panel for forming a wall of a cryogenic container
EP1698738A3 (en) * 2005-03-04 2007-11-14 REHAU AG + Co Lightweight building panel and method of production
FR3050138A1 (en) * 2016-04-18 2017-10-20 Groupe Renouveau Habitat Int Grhi MULTILAYER PANEL
WO2017182471A1 (en) * 2016-04-18 2017-10-26 Groupe Renouveau Habitat International Grhi Multilayer panel

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