Abstract:
A construction module having a multi-layered top panel, a multi-layered intermediate panel and a multi-layered bottom panel which are bonded together and desired cavities are provided through one or more of the top panel, intermediate panel and bottom panel.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to the construction art and more particularly to an improved construction module and the method of making the improved construction module. 
   2. Description of the Prior Art 
   Construction modules have long been utilized in a variety of applications such as for walls, doors, cabinets, drawer fronts, counter tops and the like. In some applications, such as aircraft, recreational vehicles and similar structures, it is desired that the modules be as light weight as possible and still strong and rigid enough to be suitable for the intended purpose. Further, such modules are often required to be visually attractive so as to provide an appealing combination with the other decor in the structure. Additionally, it is, of course, desired that the construction module be economical to purchase by the end user and therefore be econmical to fabricate so that the lower cost is passed on to the customer. 
   In many such applications there have heretofore been utilized construction modules fabricated from metal coated honeycomb, corrugated aluminum, aluminum skin over ribs or dividers, thin plywood and other such constructions. While many of these modules were light weight, they often were not rigid enough or strong enough for the purpose for which they were intended. Such lack of rigidity or strength often caused distortion of the panel when used for the intended purpose. Also, many of these prior art modules were not visually attractive from all aspects from which they were viewed. For example, even though a decorative cover could be placed on the exterior and/or interior surfaces of such structures such as doors, drawer fronts, cabinet walls and the like which are often viewed from both sides, the edge portions thereof were not as attractive as often desired. Also, many of the prior art construction modules were relatively expensive to the end user, thereby limiting the use thereof. 
   Thus, there has long been desired a construction module that is light weight, rigid, strong and visually attractive on all surfaces thereof and economical in cost. 
   SUMMARY OF THE INVENTION 
   Accordingly, it is an object of the present invention to provide an improved construction module. 
   It is another object of the present invention to provide an improved construction module that is light in weight, strong and rigid. 
   It is another object of the present invention to provide an improved construction module that is economic to fabricate and economic for purchase by the end user. 
   It is yet another object of the present invention to provide an improved construction module that can be provided with a visually attractive appearance on all surfaces thereof. 
   It is yet another object of the present invention to provide an economical method of fabricating a light weight, rigid, strong and visually attractive construction module. 
   The above, and other objects of the present invention are achieved, in a first preferred embodiment, by providing three panels which, for convenience in description, are designated as a top panel, an intermediate panel and a bottom panel. Each of the three panels is comprised of a plurality of thin sheet wooden laminate layers bonded together. A portion of the intermediate panel has been removed to define a cavity extending therethrough and the cavity is bounded by peripheral wall members thereof. The number of laminate layers in each panel may be the same or the number of laminate layers in each panel may be different depending on the application. For convenience of description, the embodiments of the present invention described herein are provided with the three panels each having three laminate layers. In fabricating the construction module of the present invention more or less than three laminate layers may be utilized in each of the panels as may be desired for particular applications. Each of the laminate layers may be, for example, on the order of one eighth inch thick, though a greater thickness or a smaller thickness may be used as desired for particular applications. 
   Each of the top panel and bottom panel has an outer surface and an inner surface and the intermediate panel has an upper surface and a lower surface. After the desired portion of the intermediate panel has been removed to define the cavity therein, the inner surface of the top panel is affixed to the upper surface of the intermediate panel and the inner surface of the bottom panel is affixed to the lower surface of the intermediate panel to provide the construction module. If desired, the outer surface of the top panel and/or the outer surface of the bottom panel may be provided with thin veneer layer replicating a wood grain or any other desired visually attractive configuration. The side surfaces of the top panel, intermediate panel and bottom panel may be left in the natural state as this appearance is often considered visually attractive or such surfaces may also be provided with a veneer layer or any other desired visually attractive configuration. The construction module of this first preferred embodiment of the present invention is a hollow core construction module thereby combining the desired light weight with a strong and rigid construction that is also visually attractive and economical to fabricate. The peripheral edges of the construction module provide a strong support for the attachment of hinges, handles or the like as necessary in main installations. The shape of the cavity in the intermediate panel may be varied as desired for particular applications. For example, in the applications wherein the construction module of the first embodiment of the present invention may be utilized as a door, an enlarged portion of the intermediate panel may be left intact in regions adjacent a peripheral edge to provide a proper mounting region for a conventional door handle to be mounted therein 
   In another preferred embodiment of the present invention, which is similar to the first preferred embodiment, the cavity in the intermediate panel may be in two portions and the two portions separated by a transverse member left intact and extending between peripheral edges. The transverse member may be positioned at any desired location in the intermediate panel to accommodate any desired attachment that may be required in particular applications. 
   In a second preferred embodiment of the present invention, a top panel, an intermediate panel, and a bottom panel are provided and may be the same as the top panel, intermediate panel and bottom panel, described above. However, in this second preferred embodiment, a preselected portion of each of the top panel and the bottom panel is also removed to define cavities extending therethrough as well as removal of a preselected portion of the intermediate panel to define the cavity extending therethrough. The cavities in the top panel, intermediate panel, and bottom panel are placed in an aligned array to provide a cavity extending through the entire construction module. A transparent member such as a pane of glass may be placed in the aligned cavity array to allow visual perception through the construction module. Alternatively, depending upon the application of the construction module, an entire window assembly may be mounted in the aligned cavity array. 
   In a third preferred embodiment of the present invention, a top panel, an intermediate panel and a bottom panel are provided and may be the same as the top panel, intermediate panel and bottom panel described above. In this third embodiment one or more portions of the top panel and/or the bottom panel are removed to provide cavities therethrough. The upper surface and/or the lower surface of the intermediate panel is provided with a decorative covering in preselected portions thereof. The decorative covering may be a fabric, a coat of paint or any other desired visually attractive configuration. The top panel and the bottom panel are attached to the intermediate panel in an aligned position so that the decorative covering on the upper surface and/or the lower surface of the intermediate panel are aligned with the cavities in the top panel and/or the bottom panel to allow viewing of the decorative covering. 
   The fabrication of the construction module of the present invention may be accomplished in a preferred method according to the principles of the present invention. The first plurality of thin sheet laminate layers in the top panel are provided with a heat activated glue therebetween. The second plurality of thin sheet laminate layers of the bottom panel are provided with a heat activated glue therebetween and the third plurality of thin sheet laminate layers of the intermediate panel are provided with a heat activated glue therebetween. The top panel and the bottom panel are positioned in the desired location on the intermediate panel and the assembly of the three panels are placed into a heated press. The press may be of any desired contour for forming the construction module into any preselected configuration. The press and the final construction module may be flat, curved, or contoured in any desired arrangement. The press is energized and activates the adhesive between the layers of each of the top panel, the intermediate panel and the bottom panel as well as forms the panels into the desired contour configuration. 
   The three layers are then removed from the press and the appropriate cavities are cut into the desired layers. After removal of the selected portions from the selected layers to define the desired cavities therein, a heat activated adhesive is applied to the inner surface of the top panel and the inner surface of the bottom panel and/or the upper and/or lower surface of the intermediate panel. The three panels are again assembled and aligned as desired and placed back into the press and the press again energized to activate the adhesive and bond the three layers together to form the construction module. The construction module may be trimmed at the peripheral edges thereof to provide the desired final configuration. 

   
     BRIEF DESCRIPTION OF THE DRAWING 
     The above and other objects of the present invention as incorporated into the preferred embodiments may be more fully understood from the following detailed description taken together with the accompanying drawing wherein similar reference characters refer to similar elements throughout and in which: 
       FIG. 1  is an exploded view of a preferred embodiment of a construction module according to the principles of the present invention; 
       FIGS. 2A and 2B  illustrate intermediate panels useful in the first preferred embodiment of the present invention; 
       FIGS. 3A and 3B  illustrate contours into which the construction module of the present invention may be formed; 
       FIG. 4  illustrates another preferred embodiment of the present invention; and, 
       FIG. 5  illustrates another preferred embodiment of the present invention. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Referring now to the drawing, there is illustrated in  FIG. 1  a first preferred embodiment of the present invention generally designated  10 . The embodiment  10  has a top panel  12 , an intermediate panel  14  and a bottom panel  16 . The top panel  12  is comprised of a first plurality of thin sheet laminate layers  12   a ,  12   b  and  12   c  bonded together by a suitable adhesive therebetween. Each of the thin sheet laminate layers may be a wood sheet and each may have a thickness on the order of one eighth of an inch. All of the first plurality of thin sheet laminate layers  12   a ,  12   b  and  12   c  are substantially coextensive. It is to be understood that the thickness of each of the first plurality of thin sheet laminate layers  12   a ,  12   b  and  12   c  may be selected as desired for particular applications and, additionally, may not all be the same thickness. Further, the number of the first plurality of thin sheet laminate layers may be greater than three or less than three as desired for particular applications. The illustration of three layers in the first plurality of thin sheet laminate layers is for illustrative purposes as is the thickness of one eighth of an inch thereof 
   A decorative veneer layer  18  may be bonded to an outer surface  20  of the top panel  12 , the top panel  12  also has peripheral edges  22  which, in embodiment  10 , define a rectangular configuration. The top panel  12  also has an inner surface  21 . 
   The bottom panel  16  is comprised of a second plurality of thin sheet laminate layers  16   a ,  16   b  and  16   c  bonded together by a suitable adhesive therebetween. Each of the thin sheet laminate layers  16   a ,  16   b  and  16   c  may be similar to the then sheet laminate layers  12   a ,  12   b  and  12   c  of the top panel  12  and may be a wood sheet and each layer, may have a thickness on the order of one eighth of an inch. All of the second plurality of thin sheet laminate layers  16   a ,  16   b  and  16   c  are substantially coextensive and, in embodiment  10 , are coextensive with the top panel  12 . It is to be understood that the thickness of each of the second plurality of thin sheet laminate layers  16   a ,  16   b  and  16   c  may be selected as desired for particular applications and, additionally, may not all be the same thickness. Further, the number of the second plurality of thin sheet laminate layers may be greater than three or less than three as desired for particular applications. The illustration of three layers in the second plurality of thin sheet laminate layers is for illustrative purposes as is the thickness of one eighth of an inch thereof. 
   A decorative veneer layer  24  may be bonded to an outer surface  26  of the bottom panel  16 . The bottom panel  16  also has peripheral edges  28  which, in embodiment  10 , define a rectangular configuration to match the rectangular configuration of the top panel  12 . 
   The intermediate panel  14  is comprised of a third plurality of thin sheet laminate layers  14   a ,  14   b  and  142   c  bonded together by a suitable adhesive therebetween. Each of the third plurality of thin sheet laminate layers  14   a ,  14   b  and  14   c  may be similar to the layers  12   a ,  12   b  and  12   c  of top panel  12  and layers  14   a ,  14   b  and  14   c  of intermediate panel  14  and may be a wood sheet and each of the layers  14   a ,  14   b  and  14   c  may have a thickness on the order of one eighth of an inch. All of the third plurality of thin sheet laminate layers  14   a ,  14   b  and  14   c  are substantially coextensive with the top panel  12  and bottom panel  16 . It is to be understood that the thickness of each of the third plurality of thin sheet laminate layers  14   a ,  14   b  and  14   c  may be selected as desired for particular applications and, additionally, may not all be the same thickness. Further, the number of the third plurality of thin sheet laminate layers may be greater than three or less than three as desired for particular applications. The illustration of three layers in the third plurality of thin sheet laminate layers is for illustrative purposes as is the thickness of one eighth of an inch thereof. 
   The intermediate panel  14  also has peripheral edges  32  which, in embodiment  10 , define a rectangular configuration to match the rectangular configuration of the top panel  12  and bottom panel  16 . The intermediate panel  14  has an upper surface  34  and a lower surface  36 . 
   In embodiment  10  a preselected portion of the intermediate panel  14  has been removed to provide an intermediate panel cavity  38  extending therethrough and defining peripheral wall members  40 ,  42 ,  44  and  46  bounding the intermediate panel cavity  38 . 
   The top panel  12 , intermediate panel  14  and bottom panel  16  are joined together to provide the construction module  48 . To join the top panel  12  to the intermediate panel  14 , a layer of adhesive is applied between the inner surface  21  of the top panel  12  and the outer surface  40  of the intermediate panel  16 . The bottom panel  16  is joined to the intermediate panel  14  by applying a layer of adhesive between the lower surface  36  of the intermediate panel  16  and the inner surface  27  of the bottom panel  16 . The preferred process and method for bonding together all of the structure to form the construction module  48  according to the principles of the present invention is described below. After joining together the up  12 , intermediate panel  14  and bottom panel  16  the peripheral edges may be trimmed to provide the desired peripheral configuration. 
   Referring now to  FIG. 2  there is illustrated therein several alternate intermediate panels useful in the construction module  48  for various applications of the present invention.  FIG. 2A  shows a plan view of an intermediate panel  50  which may be fabricated in a manner generally similar to the manner of fabricating intermediate panel  14  described above. In the intermediate panel  50  there are two selected portions  52 A and  52 B of the intermediate panel  50  that are removed to define two cavity portions  54 A and  54 B defining the intermediate panel cavity  54  therethrough. The intermediate panel cavity portions  54 A and  54 B are separated by a transverse member  56  between the peripheral walls  58  and  60 . Depending upon the particular applications for which the intermediate panel  50  may be utilized, the transverse member may provide additional support for a handle or knob (not shown) that may be desired to be attached thereto. The intermediate panel  50  may be bonded to a top panel such as top panel  12  described above and to bottom panel  16  in the manner as above described and as described below in connection with the description of the preferred process and method for fabricating a construction module such as construction module  48 . 
     FIG. 2B  shows a plan view of an intermediate panel  70  which may be fabricated in a manner generally similar to the manner of fabricating intermediate panel  14  described above. In the intermediate panel  70  there are three selected portions  72 A,  72 B and  72 C of the intermediate panel  70  that are removed to define three cavity portions  74 A,  74 B and  74 C defining the intermediate panel cavity  74  therethrough. The intermediate panel cavity portions  74 A and  54 B are separated by a first transverse member  76  between the peripheral walls  78  and  80 . The intermediate panel cavity portions  74 B and  74 C are separated by a second transverse member  82  between the peripheral walls  78  and  80 . Additionally, a supporting portion  84  may be left in the intermediate panel  70  to provide support for example, a door knob or door handle structure (not shown) that may be installed therein for the applications of a construction module utilizing the intermediate panel  70  in a door application. The intermediate panel  70  may be bonded to a top panel such as top panel  12  described above and to bottom panel  16  in the manner as above described and as described below in connection with the description of the preferred process and method for fabricating a construction module such as construction module  48 . 
   The construction module  48  as described above ans as shown in the drawing is planar in contour. However, a construction module according to the principles of the present invention may be fabricated in any desired contour.  FIG. 3A  illustrates an edge elevational view of a construction module  90  having a top panel  92 , an intermediate panel  94  and a bottom panel  96  fabricated in a manner as described above in connection with the embodiment  10  and formed into a curved contour.  FIG. 3B  illustrates an edge elevational view of a construction module  100  having a top panel  102 , an intermediate panel  104  and a bottom panel  106  fabricated in a manner as described above in connection with the embodiment  10  and formed into a sinusoidal type contour. The contours illustrated in  FIGS. 3A and 3B  are only two of the many possible, contours that may be desired for particular applications of the present invention. 
     FIG. 4  illustrates an exploded view of another embodiment generally designated  110  of a construction module  112  according to the principles of the present invention. The embodiment  110  is generally similar to the embodiment  10  described above and is generally fabricated in the same manner and has a top panel  114 , an intermediate panel  116  and a bottom panel  118 . In the embodiment  110  a decorative layer  120  on a preselected portion of the upper surface  122 . A similar decorative layer may be placed on the bottom surface  124 . A preselected portion indicated by the dotted lines  119  may be removed to define intermediate panel cavity  123  therethrough to provide a lighter weight tot the construction module  112 . 
   A preselected portion  126  of the top panel  114  is removed to define a top panel cavity  128  extending therethrough bounded by the top panel peripheral walls  130 ,  132 ,  134  and  136 . 
   A preselected portion  138  of the bottom panel  118  is removed to define a bottom panel cavity  128  extending therethrough bounded by the bottom panel peripheral walls  142 ,  144 ,  146  and  148 . The bottom panel cavity  140  is provided in those configurations of the present invention wherein a decorative layer on the bottom surface of the intermediate panel  116 . 
   The top panel  114  is bonded to the intermediate panel  116  in a manner so that the top panel cavity  138  is aligned with the decorative layer  120  on the intermediate panel  116 . Similarly, if a decorative layer is provided on the lower surface  124  of the intermediate panel  116 , the bottom panel  118  is bonded to the intermediate panel  116  so that the bottom panel cavity  140  is aligned with the decorative layer on the lower surface  124  of th intermediate panel  116 . 
     FIG. 5  illustrates an exploded view of another embodiment generally designated  150  of a construction module  152  according to the principles of the present invention. The embodiment  150  is generally similar to the embodiments  10  and  110  described above and is generally fabricated in the same manner and has a top panel  154 , an intermediate panel  156  and a bottom panel  158 . In the embodiment  150  a preselected portion  160  of the intermediate panel  156  is removed to define an intermediate panel cavity  162  therethrough bounded by the peripheral walls  164 ,  166 ,  168  and  170 . Additionally, if desired, another preselected portion indicated by the dotted lines  161  may be removed to define a second intermediate panel cavity  1163  therethrough to provide a lighter weight tot the construction module  152 . 
   The top panel  156  is generally similar to the top panel  114  of embodiment  110  and has a top panel cavity  172  extending therethrough. The bottom panel  158  is generally similar to the bottom panel  118  of embodiment  110  described above and has a bottom panel cavity  174  extending therethrough. 
   The top panel  154  is bonded to the intermediate panel  156  in a manner so that the top panel cavity  172  is aligned with the intermediate panel  162  on the intermediate panel  156 . Similarly, the bottom panel  158  is bonded to the intermediate panel  156  so that the bottom panel cavity  174  is aligned with the intermediate panel cavity  162  of intermediate panel  116 . A transparent member (not shown) may be placed in the aligned cavities  162 ,  172  and  174  to provided a window type configuration. Alternatively, depending upon the particular application for the construction module  152 , an entire widow assembly may be mounted in the aligned cavities  162 ,  172  and  174 . 
   The preferred method of fabricating the construction module of the present invention utilizes a heated, contoured press. According to this preferred method, a first plurality of thin sheet layers is assembled to form the top panel and a heat reactive adhesive is applied between the first plurality of thin sheet layers. If a veneer layer is desired it is applied to the outer surface of the top most layer and the heat reactive adhesive is applied therebetween. Similarly, a second plurality of thin sheet layers is assembled to form a bottom panel and a heat reactive adhesive is placed between the second plurality of thin sheet layers. If a veneer layer is desired, it is placed adjacent the lowest most layer and a heat reactive adhesive is placed therebetween. A third plurality of thin sheet layers is assembled to form an intermediate panel and a heat reactive adhesive is placed between the third plurality of thin sheet layers. The decorative layer, if required for the desired construction module is placed adjacent the uppermost layer of the intermediate panel and/or the lowest most layer of the intermediate panel and the heat reactive adhesive is placed therebetween The intermediate panel is placed between the top panel and the bottom panel in an aligned position as may be required by the structure of the particular construction module as described above. The aligned top panel, intermediate panel and bottom panel is placed in a heated press to bond together the first plurality of thin sheet layers, and to bind together the second plurality of thin sheet layers and to bond together the third plurality of thin sheet layers and form the top panel, intermediate panel and bottom panel into the desired contour. The top panel, intermediate panel and bottom panel are removed from said heated press and are separated from each other. The selected portions of each of the tp, intermediate panel and bottom panel are removed as desired depending on the particular construction module panel configuration and a heat reactive adhesive is placed between the inner surface of the top panel and the upper surface of the intermediate panel and a heat reactive adhesive is placed between the inner surface of the bottom panel and the lower surface of the intermediate panel. The assembled top panel, intermediate panel and bottom panel is placed back into the heated press to bond together the top panel, intermediate panel and the bottom panel to form the desired construction module. The construction module is removed from the heated press and the peripheral edges thereof may be trimmed as desired to the final configuration. 
   This concludes the description of the preferred embodiments of the present invention. From the above it can be seen that there has been described an improved light weight, strong and rigid construction module that may be finished to provide any desired visually attractive appearance. 
   While particular embodiments and applications of the present invention have been above described and illustrated, the present invention is not limited to the precise construction and arrangements disclosed. Those persons knowledgeable in the art may conceive of certain modifications, changes and variations in the detailed embodiments disclosed above as illustrative, to suit particular circumstances or products to be formed. The invention is therefore not intended to be limited to the preferred embodiments depicted, but only by the scope of the appended claims and the reasonably equivalent apparatus and methods to those defined therein.