Abstract This disclosure involves a form of prefabricated structure such as commercial or industrial buildings, houses or enclosures employing an external skin bonded to an intermediate structural and insulating filler with an inner surface skin similarly bonded to the filler material. The external skins are preferably resin bonded glass fiber and the intermediate filler composes a random honeycomb structure made of cellulosic material, such as individual pieces of paper of random size each rigidified and bonded to adjacent pieces by a resinous binder which is compatible with the binder of the skins. The structure is shown in continuous panels and actually three dimensional structure configurations as well as discrete structural elements which may be used to replace comparable structural elements normally made of wood. Disclosed also are processes for continuous manufacture of structures employing the concept of this invention either in the factory or on site. The same basic structure is shown in various configurations. Illustrated are a number of panel sections employing the same structure arrangement but different filler density whereby the load bearing strength of the panel may be controlled and its insulating properties varied as well. Structural strength can also be varied by changing the dimensions and concentrations of resin/fiberglas of either or both external skin surfaces. Disclosed also are individual structural elements produced from waste paper material and resin bonded skins.
A STRUCTURAL MEMBER COMPRISING A CONTINUOUS SKIN OF RESIN BONDED FIBERGLASS ENCLOSING A FILLER OF RANDOM ORIENTED CELLULOSITIC PARTICLES OF AT LEAST 70% CELLULOSITIC CONTENT RIGID FIED WITH RESIN COMPATABLE WITH THE SKIN RESING AND IN BONDED ENGAGEMENT THEREWITH; SAID PARTICLES IN THREE DIMENSIONAL RANDOM ORIENTATIONS INTERSECTING IN IRREGULAR EDGE TO EDGE, SURFACE TO SURFACE AND EDGE TO SURFACE JUNCTIONS WITH EDGE FIBERS OF ADJACENT PARTICLES IN BONDED ENGAGEMENT CONSISTUTING A MASS OF RIGID MATERIAL AND DEFINING VOID AREAS IN THE ORDER OF 80 TO 94% OF THE VOLUME OF THE FILLER.
Claim 2
Dependent Claim
92 words
A STRUCTURAL MEMBER COMPRISING A CONTINUOUS SKIN OF RESIN BONDED FIBERGLASS ENCLOSING A FILLER OF RANDOM ORIENTED CELLULOSITIC PARTICLES OF AT LEAST 70% CELLULOSITIC CONTENT RIGID FIED WITH RESIN COMPATABLE WITH THE SKIN RESING AND IN BONDED ENGAGEMENT THEREWITH; SAID PARTICLES IN THREE DIMENSIONAL RANDOM ORIENTATIONS INTERSECTING IN IRREGULAR EDGE TO EDGE, SURFACE TO SURFACE AND EDGE TO SURFACE JUNCTIONS WITH EDGE FIBERS OF ADJACENT PARTICLES IN BONDED ENGAGEMENT CONSISTUTING A MASS OF RIGID MATERIAL AND DEFINING VOID AREAS IN THE ORDER OF 80 TO 94% OF THE VOLUME OF THE FILLER.
Claim 3
Dependent Claim
36 words
The combination in accordance with claim 1 wherein said cellulostic fibers comprise discrete pieces of fragmented paper with resin rigidified central portions in partially creased form to produce columnar portions for transmitting load through said filler.
Claim 4
Dependent Claim
114 words
A structural member comprising a continuous skin of resin bonded sheet material defining a closed shape in cross section and a filler therein in bonded engagement with the skin and comprising a mass of random oriented celluloSe particles in resin rigidified condition and defining a plurality of random positioned void regions constituting between 80 and 94% of the filler by volume; said particles in three dimensional random orientations intersecting in irregular edge to edge, surface to surface and edge to surface junctions with edge fibers of adjacent particles in bonded engagement constituting a mass of rigid material; said particles being in partly creased condition to produce columnar portions for transmitting load through said filler.
Claim 5
Dependent Claim
114 words
A structural member comprising a continuous skin of resin bonded sheet material defining a closed shape in cross section and a filler therein in bonded engagement with the skin and comprising a mass of random oriented celluloSe particles in resin rigidified condition and defining a plurality of random positioned void regions constituting between 80 and 94% of the filler by volume; said particles in three dimensional random orientations intersecting in irregular edge to edge, surface to surface and edge to surface junctions with edge fibers of adjacent particles in bonded engagement constituting a mass of rigid material; said particles being in partly creased condition to produce columnar portions for transmitting load through said filler.
Claim 6
Dependent Claim
13 words
The combination in accordance with claim 3 wherein said sheet material comprises fiberglas.
Claim 7
Dependent Claim
20 words
The combination in accordance with claim 3 wherein said skin is in the order of 0.05 to 0.10 inch thick.
Claim 8
Dependent Claim
27 words
The combination in accordance with claim 3 wherein said filler has a ratio of resin to cellulostic particles by weight in the order of 1.9 to 5.1.
Claim 9
Dependent Claim
15 words
The combination in accordance with claim 3 wherein said filler comprises fragmented particles of paper.
Claim 10
Dependent Claim
23 words
The combination in accordance with claim 3 wherein said particles of paper have a mean particle size of 2 inches across or less.