Patent ID: 6253530
Filing Date: 2001-07-03
Classification: E04B,E04C,Y10T

Abstract:
A modular structural panel system which includes individual modular interconnectable panels to assemble floors, interior and exterior walls, ceilings and roofing members for erecting buildings, houses and other structures without the need for conventional framing members, said system comprising:a plurality of essentially identical structural panels, each panel of said panels including;a first skin having a first surface and a second surface on opposing sides thereof;a second skin having a first surface and a second surface on opposing sides thereof, wherein at least one of said first and second skins further comprises a water resistant, green board gypsum sheet;a honeycomb core comprising a thermally expanded paper web which is impregnated with a phenolic resin and providing a plurality of honeycomb cells and having first and second sides corresponding to opposing sides of said honeycomb cells;a first adhesive layer bonding the first surface of the first skin to said first side of said honeycomb core; anda second adhesive layer bonding the first surface of said second skin to said second side of said honeycomb core, said first and second adhesive layer each comprising a moisture-cured application of a non-volatile adhesive which is curable under ambient temperatures;at least one of said first and second adhesive layers being substantially continuous over the associated first surface having a thickness of approximately five millimeters and having been cured under pressure distributed evenly over said first surface; in which:each of said honeycomb cells further comprises a plurality of web members, each of said web members further including first and second opposing surfaces and first and second opposing ends thereof;said first adhesive layer further comprising a first plurality of adhesive welds bonding a substantial portion of each of said first and second web surfaces to said first surface of said first skin, said adhesive weld being disposed substantially at said first end of each said web;said second adhesive layer further comprising a second plurality of adhesive welds bonding a substantial portion of each of said first and second web surfaces to said first surface of said second skin, each adhesive weld being disposed substantially at said second end of each said web; andeach weld of said first and second plurality of adhesive welds including a fillet having an approximate depth of at least one-sixteenth (1/16) of an inch;wherein a structural member having significant resistance to creep between each of said first and second face skins and said honeycomb core as provided by said first plurality and said second plurality of adhesive welds.