Composite Stiffener

Abstract

Solid panels, composite panels, sandwich panels, tabletops, countertops, and doors made with any type of inner core material tend to warp, bend, or twist during the service life of the product. Prior solutions included adding, inserting, or embedding steel rods, steel frames, even steel pipes in an effort to reduce warping, but this adds considerable weight to the end product introducing a whole new set of problems. Aluminum tubes or extrusions are a lighter weight alternative to steel but also come with its own set of challenges, especially for sanding and gluing. This invention will address these issues while remaining lightweight, increasing strength, and preventing and tendencies to warp.

Description

BACKGROUND OF INVENTION

This invention is designed to reinforce hollow core or any other type of core panel. Conventional hollow core doors have a tendency to warp and otherwise fail over a short amount of time. This invention is designed as a composite building material which can, but is not limited to, be used in conjunction with hollow cores, honeycomb cores, paper cores, fiberglass cores, or any other panel core to reinforce the panel's structural stability. The stiffener can be embedded inside of the panel, or post/beams, along with the core type of choice or replace the core all together with the composite stiffener.

The composite stiffener comprises of multiple layers (at least 3) of aluminum, formica, plastic, sheet metals, fiberglass, or other strengthening materials; plywood, veneer, multiple layers of veneer, MDF, or other wood products for adequate bonding surface; and honeycomb core, paper core, hollow core, or other filler materials. The materials listed above can alternate and be adhered with an adhesive. Once the adhesive is fully cured, the layers of materials can be cut length-wise or width-wise perpendicular to the width edge of the sandwiched materials. Thickness of the section being cut is determined by the thickness of the core used in the panel the composite stiffener is intended for. The section that was previously cut off, is the composite stiffener, to be placed with the end grain to each surface of the panel requiring the stiffener. With the end grain of the stiffener facing the inner surface of the panel, or the stiffener layers are perpendicular to the surface of the panel, ensures the panel containing the stiffener will remain straight and not warp, bend, twist, or otherwise fail.

SUMMARY OF INVENTION

This invention is designed to reinforce hollow core or any other type of core panel. Conventional hollow core doors have a tendency to warp and otherwise fail over a short amount of time. This invention is a composite building material which can, but is not limited to, be used in conjunction with hollow cores, honeycomb cores, paper cores, fiberglass cores, or any other panel core to reinforce the panel's structural stability. The stiffener can be embedded inside of the panel along with the core type of choice or replace the core all together with the composite stiffener.

The composite stiffener can be comprised of multiple layers of aluminum, formica, HPL, plastic, fiberglass, sheet metals, or other strengthening materials; plywood, veneer, multiple layers of veneer, alternating grain veneers, MDF, or other wood products, or even mineral boards such as gypsum board; and honeycomb core, paper core, hollow core, or other core materials. The materials listed above can be layered in an alternating fashion and adhered together using any type of adhesive necessary, forming one multi-layered panel. The materials used in the various layers of this panel can be altered to fit the exact need required of the finished composite stiffener. For example, starting from the bottom face to the top face of this panel could be layered as follows; sheet aluminum, plywood sheet, honeycomb core, plywood sheet, sheet aluminum. Another variation could be; plywood sheet, sheet aluminum, plywood sheet, honeycomb core, plywood sheet, sheet aluminum, plywood sheet. There are many different combinations of materials that can be used to create a sturdy stiffener. The plywood creates a sturdy base to create the stiffener but also to ensure a thorough bond with the final panel. More or less layers of materials can be used depending on how strong the stiffener needs to be.

The multi-layered panel can be cut parallel to the long edge and perpendicular to the width of the panel. The material being cut off can vary in thickness depending on the specific need. The material cut off of the multi-layered panel is the composite stiffener. The composite stiffener can be placed inside of a panel with the end grains on the top and bottom face of the interior of the panel. The layers of the composite stiffener should be perpendicular to the final panels faces to provide optimal rigidity.

Optional provisions have been added to include sections of the stiffener that are solid wood that can be placed wherever needed to create an anchoring point for various hardware or for cut outs.

The composite stiffener could be comprised of alternating plywood and aluminum or a strengthening material and a soft material for a better bonding surface. The composite stiffener can be used as framing for various applications. It could function as a frame for doors, doors with light openings, patio doors, french doors, window frames, stud framing, any type of building materials. If used for panels, doors, or window frames with windows dowels, dog bones, or other connectors can be used in the corners to prevent any weak points. It is preferable, but not limited to, for the layers of strengthening material can run parallel to the wall to reduce the amount of thermal bridging.

Optional provisions have been made to slice the adhered alternating sheets and adhere them together in a way that the layers of alternating sheet goods are perpendicular to each other. This variation would greatly increase the strength of the stiffener and prevent any flexing in any direction. It can include an insulating material to decrease the thermal bridging through the stiffener. The insulating material, like Styrofoam, can be different densities to provide more insulating qualities or more rigidity depending on the specific need.

Skins can cover every side of the stiffener when being used as posts, beams, or other structural building materials. The skins containing the stiffener can reduce coupling under pressure. It can appear to be solid wood, but it will be much stronger. It can then go through a machining process to create tongue and groove, ship lap, or other profiling. Can be profiled on the edge or corner similar to a stile and rail door. This will create a stile and rail door that is very strong and straight with reinforced materials. This invention could be used to replace the stiles and rails in stile and rail doors. Conventional stile and rails are created out of solid wood, which has a tendency to move over time, the composite stiffener will not allow the materials to move and remain rigid for a lifetime. The strength created by this composite stiffener will provide useful for doors and panels with windows.

SHORT FIGURE DESCRIPTION OF DRAWINGS

FIG. 1 is a three dimensional view of the various layers of sheet goods required for the composite stiffener.

FIG. 2 is a three dimensional view of the various layers of sheet goods adhered together.

FIG. 3 is a three dimensional view of a slice cut from the layered panel.

FIG. 4 is a three dimensional view of the composite stiffener being properly placed into a panel.

FIG. 5 is a three dimensional view of the stiffener being glued a second time to additional layers of strengthening material.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The composite stiffener is comprised of multiple layers of sheet goods FIG. 1. At least one layer of strengthening material such as sheet aluminum, sheet metals, plastics, fiberglass, formica, HPL, or other strengthening materials; at least one layer of gluing surface material such as, plywood, veneer, alternating grain veneer, or other wood products; and an optional layer or layers of core materials such as honeycomb core, hollow core, fiberglass core, paper core, or other core materials. The various layers can then be adhered together using any desired adhesive FIG. 2. Once the adhesive is cured, the resulting panel can then be sliced through the thickness of the panel, parallel to the length and perpendicular to the width. The cut off material is the composite stiffener FIG. 3. The stiffener can then be rotated so the layers are perpendicular to the face of the panel requiring the composite stiffener FIG. 4. Additionally, the composite stiffeners can be layered with alternating strengthening material to greatly reduce the amount of flex and increase overall strength and rigidity FIG. 5.

Claims

1. The composite stiffener is comprised of multiple layers of various sheet goods; reinforcing materials such as sheet aluminum, sheet metals, formica, HPL, fiberglass, plastics, or other reinforcing materials; gluing surfaces such as plywood, veneer, multiple layers of veneer, MDF, or other wood products; and a core material such as honeycomb core, hollow core, paper core, fiberglass core, or other core materials.

2. In accordance with claim 1, the layers of various sheet goods can be adhered together with an adhesive of choice creating a solid panel. The resulting panel can then be cut through the thickness of the panel, parallel to the long side. The material cut off is the composite stiffener to be used in other panels, posts, beams or other building materials.

3. In accordance with claim 1, the composite stiffener can be placed in conjunction with other core materials inside of a panel or the panel can have a core made completely of composite stiffeners. The stiffener can be placed with the end grain facing the surfaces. The stiffener should be perpendicular to the exterior skin of the final panel.

4. In accordance with claim 1, the layers of various sheet goods can vary depending on the specific need of the composite stiffener. More or less layers of materials can be used depending on how strong the stiffener needs to be.

5. In accordance with claim 1, sections of each layer could be replaced with sections of solid wood to create anchoring points for hardware, drilling, or even cut-outs.