US 2055032 A
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Sept. 22, 41936. J. F. JoHNsoN PANEL'. BOARD Filed April 50, `195:54
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. Patented Sept. 22, 1936 PANEL BOARD Jonas F. Johnson, Chicago. lll., aaolgnor of'one- 'half to Fred Degian, Elmhurst, Ill.
Apniiootionaprii so, 19:4. serial No. 123,039
4 claim. (ci. en -1s) My invention pertains to fabricated composite panel boardsof the wall-board type. My board may be used as wall, furniture and door paneling, partitions, wall surfacing, table and counter tops, .and the like, and in general as a substitute for wood panels.
Where a wood surface veneer is'carried on a soft ilbre backing such as a pressed bagasse board, there is ordinarily danger of the veneer cracking and pulling apart when subject to dry air, or penetrated by nails, of warping when damp, and of being dentedinto the soft backing. One object of my invention is to avoid or lessen these dangers. metal sheet between the veneer and backing.
A further object is to adhere these three elements-the backing, the metal sheet and the veneertogether rmly and permanently, overcoming the problem of making an adhesive hold to a metal surface. I solve this problem by adhering the veneer directly to the libre board roughV perforatio'ns in the intervening metal eet.
My resulting panel' board has many advantageous features. It is light in weight because the nbre backing is light and the veneer and metal sheet add little weight per square foot. It
` has a higher tensile strength in lall directions of its plane, because of the reinforcing effect of the metal sheet. T'he veneer and metal sheetl greatly increaseA the general strength and rigidneer or the backing, this because of the intimate securement of the reinforcing metal sheet thereto. It may present a real, and not an imitation, wood surface but the wood veneer is protected -against ill effects of either excessive moisture or dryness, because of the 'reinforcing effect of the metal sheet.- My panel retainsl the heat insulating function of the bagasse board backing, and
'to this is added that of the wood veneer. It also v'retains thesound insulating property of the backing. The re resistance of my panel is'increased-by the metalsheet over that ofthe slowburning fibre backing; and if desired the firel resistance may be further increased by a sup-y plemental sheet of asbestos.
,The metal sheet will conduct away and dissipate localized appli- This I accomplish by a my single-surfaced panel;
cations of extreme -heat such, 4for example, as might result from a short circuit in electric wiring, and this will tend to prevent fires. m panel readily lends itself to a double-surfaced panel where the fibre backing becomes a core between^ two veneer sheets and metal sheets, which may economically be used for partitions, door panels, and the like. My panel is economical to manufacture.
'I'he foregoing, together with further objects,
features and advantages of my invention are set forth in the following description of specific embodiments thereof which are illustrated in the accompanying drawing, wherein:
Fig. 1 is a perspective view of a fragment of Fig. 2 is an exploded" perspective view thereof;
Fig. `3 is a cross-section taken on the line l-I 'of Fig. 1;
Fig.- 4 is aperspective view of a fragment of a modified form` of paneling where the metal sheet is within the backing board;
Fig. 5 is a similar view of another modi'cation having an auxiliary layer'of sheet asbestos; and Fig. 6 is a similar view of double-surfaced panel. l
Referring nrst to the form of Figs. 1, 2 and 3, my panelvboard i0, which it will be understood is factory assembled and shipped in convenient standard sizes, comprises. three major layers. Each layer is self-contained and pre-formed and preferably cut to the standard size of the resulting panel before assembly. The flrst layer is a main body or backing Il which may be a pressed' bagasse board such as manufactured by the Celotex Company of Chicago, under the trademark Celotex, ora wood fibre board such as is made from steam-exploded yellow pine chips pressed into sheet board form as, for example, is manufactured by 'I'he Masonlte Corporation of Chicago under the trade-mark Masonite, or cork board or` any other of the many known types of light insulating boards of relatively soft fibrous material. I' contemplate however that for certain purposes a backing of the plaster-board ,or plywood types may/ be substituted.
I'he second or intermediate layer is a perforated metal sheet I2 which will later be described.
1 contemplate that other suitable materiels may Abut also in the plane of the panel.
be either substituted for the wood veneer or applied to its outer surface to meet specic requirements or give desired effects, as for example, linoleum or rubber flooring, for bathroom walls or card table tops or counter tops and marbleized linoleum for store or counter fixtures. Where leather, canvas, ornamental fabrics or other relatively limp or plastic surfacing is desired for decorative effect, they are preferably applied to the outer surface of the veneer, which may be done before assembly, or after assembly or after the panel is installed.
Referring again to the metal sheet I2, I prefer to use thin rolled sheet steel having overall stamped-out perforations I4. In a typical panel bOard having a backing sheet Il of say inch thickness and a hard wood venner 13 of 315 inch thickness, the metal sheet may be 24 to 28 gauge with 11g inch perforations spaced ten to the inch.
A layer of adhesive I such as glue or adhesive cement is applied preferably both to the inner surface of the veneer i3 and the outer surface oi' the backing Il. The backing and veneer are thensuperposed with the metal sheet between themf and the assembly is put in a press or passed between rollers. layers to adhere together and also forces the adhesive into the perforations.
If the adhesive be applied directly only to the backing, some of the adhesive is forced through the perforations and into contact with the veneer in the areas opposite the respective perforations. Also to a certain extent the adhesive flows between the lands of the metal sheet and the inner surface of the veneer and away from each perforation, to increase the area of contact of the adhesive with the veneer, in addition to the aggregate area of the perforations.
If the adhesive be applied directly only to the veneer, it will similarly be forced through the perforations into contact with the backing. Whichever of these three methods is followed, the perforations will be permanently lled by the adhesive. When the adhesive contracts upon setting it will thereby tend to pull the veneer and backing more rmly together with the metal sheet therebetween.
While I contemplate that there will preferably be a direct surface-to-surface cementing of the metal sheet to the backing board and to the veneer, I recognize that it is diihcult to get a good adherence to a metal surface. The direct adherence of the veneer to the backing by the adhesive through the perforations'provides a. iirm permanent assembly which does not depend upon the less reliable adhesion to the surface of the metal.
I have previously mentioned that the glue or other adhesive upon setting and drying will contract to null the veneer and the backing together' transversely of the plane of the panel. A slight transverse deformation'of the backing and veneer is indicated in the cross-section of Fig. 3. But -the contraction of the glue upon drying is not only transversely of the plane of the panel, Thus the slug of glue which occupies each perforation, upon drying, will contract to pull itself away from the margins of the perforations, leaving a slight annular space l1 which aords a certain amount of play in the plane of the panel. Thereare situations where the wood 'veneer will tend to expand undermoisture or the backing will tend to expand under moisture or under heat the wood will tend to dry while the metal expands. These This compression causes the .panel where the metal sheet and veneer are applied to both sides of the backing board, which then becomes a core. VThis is particularly adapted for use as a partition, door panel, or the like.
Fig. 4 shows a modification Where the veneer is directly adhered to the outer surface of the backing board and the metal sheet is inserted between, and adhered to the inner surfaces of, two plies of the backing board. If desired, a veneer may be applied also to the exposed back surface of the backing board to provide a doublesurfaced panel. i
In the modification of Fig. 5, I have included a layer of sheet asbestos I6 which is inserted either between the metal sheet and the backing board or, as specifically illustrated, between the metal plate and the veneer. In the latter case, the veneer is directly adhered to the asbestos sheet. Such a medication may be used when greater ire resistance is desired.
1. As an article of manufacture, a composite panel handleable as a unit and comprising a preformed backing of stiif compressible bre board, a pre-formed surfacing veneer of virgin wood, a pre-formed metal sheet, wholly conned between the planes of its own surfaces, interposed immediately between the board and the veneer and in surface contact therewith, overall perforations in the metal sheet, and an adhesive adhering to the juxtaposed surfaces of the board and of the veneer and extending therebetween through the perforations for holding the board, metal sheet and veneer in permanently assembled fixed relation as a unitary panel, the inner surface of the veneer at the perforations being substantially co-planar with the inner surface thereof between the perforations.
2. A double-surfaced composite panel of the wall-board type comprising a core layer of Stiff compressible fibre board, an exposed surfacing sheet of wood veneer at each side of the core, an all-over perforated metal sheet between and in surface contact with the core layer and each of said veneer sheets, and an adhesive adhering to an outer surface of the core and to the inner surfaces of the respective veneer sheets and extending through the perforations in the ,metal sheet for permanently holding the veneer sheets to the core with the metal sheets therebetween.
3. A composite panel of the'wall-board type comprising a backing of stiff, compressible ilbre board, a second layer of self-supporting sheet material, a layer of perforated flat metal, wholly conned between the planes of its own surfaces, coextensive with the panel and intermediate, and in surface contact with, the bre board and the second l'a'yer, and an adhesive applied only to the backing sheet extending through the perforations in the metal layer and directly adhering the fibre board to the second layer.
4. As an article of manufacture, a composite genoeg '-3 panel handleable as a unit and comprising a. preformed backing lof etltl! compressible nbre board vo1' e. thicknes ofthe order 'of $5", a pre-farmed lo all pertorationsin the metal cheet. and en ad hcaive adhering to the juxtaposed surfaces of the board and ofthe veneer and extending therebetween through the perforations for holding the bom-metal-ahcet and veneer in permanently assembled ilxed relation as a unitary panel, the inner surface of the veneer at the perforations being substantially co-planar with the innen surtace thereof between the perforations.-
JONAS F. JOHNSON. 10