Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02344617 2008-07-16
PATENT
Express Mail No. EK106405960US
Attorney Docket No. 4619.03
ENCLOSED RETRACTABLE PANEL MADE FROM CELL-INSIDE-A-CELL
HONEYCOMB MATERIAL
BACKGROUND OF THE INVENTION
a. Field of the Invention
The instant invention is directed toward an enclosed retractable panel made
from an
expandable and contractible honeycomb material. More specifically, it relates
to an enclosed
retractable panel of expandable and contractible honeycomb material formed
from elongated
tubular cells where at least one of the elongated tubular cells comprising the
panel is itself multi-
cellular.
b. Background Art
It is well known that cellular panels provide excellent coverings for
architectural
openings. For example, U.S. Pat. No. 5,482,750 discloses a multi-cellular
honeycomb insulating
panel. Another type of retractable cellular panel is disclosed in U.S. Pat.
No. 4,603,072. Still
another type of honeycomb insulating panel is disclosed in U.S. Pat. Nos.
4,795,515 and
4,871,006. In the `515 and `006 patents, a plurality of attaching strips join
two sheets of fabric
along corresponding pleat lines formed in each of the two sheets. U.S. Pat.
No. 5,228,936
discloses yet another insulating panel wherein a strip connects adjacent
sheets of fabric.
Various machines are known that are capable of manufacturing cellular panels
at high
speeds. For example, U.S. Pat. No. 4,450,027 discloses an apparatus for
manufacturing cellular
panels. Related U.S. Pat. No. 4,631,108 issued from a continuation-in-part of
the application
that eventually issued as the `027 patent.
Cellular honeycomb panels have been manufactured heretofore having multiple
cells
juxtaposed such that in order to pass through the honeycomb panel along a path
that is
perpendicular to the plane of the panel one must pass through more than one
cell. A panel of
1
CA 02344617 2008-07-16
Express Mail No. EK106405960US
'Attorney Docket No. 4619.03
this type is disclosed in the `750 patent mentioned above. These panels have
excellent insulating
properties, but may be rather thick.
It is also known to put insulating materials within walls (for example,
between the studs
separating an inner wall from an outer wall) to reduce heat and noise transfer
through the wall.
There remains a need, however, for additional insulating materials that both
inhibit heat and
noise transfer and make efficient use of limited available space.
SUMMARY OF THE INVENTION
It is desirable, therefore, to be able to form a retractable panel to be
affixed over an
architectural opening or enclosed within a wall, ceiling, or floor, such that
the panel includes a
multi-cellular honeycomb insulating panel wherein more than one tubular cell
is encountered
while passing perpendicularly through the panel, and further wherein the
overall thickness of the
panel is comparable to the thickness of a honeycomb insulating panel that is a
single tubular cell
thick.
Accordingly, it is an object of the disclosed invention to provide an improved
retractable
panel to be affixed over an architectural opening or enclosed within a wall.
The instant invention includes a retractable panel to be affixed over an
architectural
opening or enclosed within a wall. The retractable panel comprises an
expandable and
contractible honeycomb panel, itself comprising a plurality of adjacent,
embedded tubular cell
units, including at least a top embedded tubular cell unit and a bottom
embedded tubular cell
unit. The embedded tubular cell units are affixed together one on top of
another, and each cell
unit comprises an interior tubular cell inside an exterior tubular cell.
Further, each embedded
tubular cell unit is constructed of at least one strip of foldable and
creasable material, and has a
front side and a rear side. At least one of the front side and the rear side
of each of the
embedded tubular cell units comprises multiple layers of material. A rigid top
slat is affixed to
2
CA 02344617 2001-04-18
Express Mail No. EK106405960US
Attorney Docket No. 4619.03
the top embedded tubular cell unit, and a rigid bottom slat is affixed to the
bottom embedded
tubular cell unit.
In another form, the retractable panel comprises an expandable and
contractible
honeycomb panel that includes a plurality of adjacent, embedded tubular cell
units affixed
together one on top of another, including at least a top embedded tubular cell
unit and a
bottom embedded tubular cell unit. Eac:h embedded tubular cell unit comprises
a family of
neighboring tubular cells arranged one inside another, and the family includes
members
comprising an exterior tubular cell and am interior tubular cell. Each member
of the family of
neighboring tubular cells comprises a first portion having a front side and a
rear side, a front
second portion having a first inside edge and being folded partially over the
front side of the
first portion, a rear second portion having a second inside edge and being
folded part'tally over
the rear side of the first portion, in such a manner that the first inside
edge of the front second
portion and the second inside edge of the rear second portion approach but do
not overlap
each other. Permanently set folds exist between the first portion and the
respective inside
edges of the front and rear second portions, separating the respective second
portions and the
first portion in a manner biasing the second portions toward the first
portion. Each member of
the family of neighboring tubular cells is affixed to a next neighboring
member of the family. A
rigid top slat is affixed to the top embedded tubular cell unit, and a rigid
bottom slat is affixed
to the bottom embedded tubular cell unit.
A more detailed explanation of the invention is provided in the following
description
and cLzims and is illustrated in the accornpanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a cross-sectional view of an
elongated tubular cell used to form a honeycomb
panel according to a first embodiment of the instant invention;
Fig. 2 is a cross-sectional view of a plurality of elongated tubular cells
according to Fig.
1;
Fig. 3 is an isometric view of a portion of a honeycomb panel formed using
elongated
tubular cells according to Fig. 1; -
Fig. 4 is a cross-sectional view of an elongated tubular cell used to form a
honeycomb
panel according to a second embodiment of the instant invention;
3
CA 02344617 2001-04-18
Express Mail No. EK106405960US
Attorney Docket No. 4619.03
Fig. 5 is a cross-sectional view of a plurality of elongated tubular cells
according to Fig.
4;
Fig. 6 is an isometric view of a portion of a honeycomb panel formed using
elongated
tubular cells according to Fig. 4;
Fig. 7 is a cross-sectional view of an elongated tubular cell used to form a
honeycomb
panel according to a third embodirnent of the instant invention;
Fig. 8 is a cross-sectional view of a plurality of elongated tubular cells
according to Fig.
7;
Fig. 9 is an isometric view of a portion of a honeycomb panel formed using
elongated
tubular cells according to Fig. 7;
Fig. 10 is a cross-sectional view of an elongated precursor tubular cell used
to form a
honeycomb panel according to a fourth embodiment of the instant invention;
Fig. 11 is a cross-sectional view of a plurality of elongated precursor
tubular cells
according to Fig. 10;
Fig. 12 is an isometric view of a portion of a honeycomb panel formed using
elongated
precursor tubular cells according to Fig. 10;
Fig. 13 is an isometric view of a retractable cover for an architectural
opening
incorporating a honeycomb panel formed using elongated precursor tubular cells
according to
Fig. 10;
Fig. 14 is a cross-sectional view of an elongated tubular cell used to form a
honeycomb
panel according to a fifth embodiment of the instant invention;
Fig. 15 is a cross-sectional view of a plurality of elongated tubular cells
according to
Fig. 14; Fig. 16 is an isometric view of a portion of a honeycomb panel formed
using elongated
tubular cells according to Fig. 14;
Fig. 17 is a cross-sectional view of an elongated tubular cell used to form a
honeycomb
panel according to a sixth embodiment of the instant invention;
Fig. 18 is a cross-sectional view of a plurality of elongated tubular cells
according to
Fig. 17;
Fig. 19 is an isometric view of a portion of a honeycomb panel formed using
elongated
tubular cells according to Fig. 17;
4
CA 02344617 2001-04-18
Express Mail No. EK106405960US
Attorney Docket No. 4619.03
Fig. 20 is a fragmentary isometric view of a wall section depicting a first
honeycomb
panel installed between studs and in an ex-panded configuration, and an
uninstalled, second
honeycomb panel adjacent to the wall section and in a contracted
configuration;
Fig. 21 is similar to Fig. 20, but depicts the second honeycomb panel in an
expanded
configuration;
Fig. 22 is similar to Figs. 20 and 21, but depicts the second honeycomb panel
installed
between studs of the wall section;
Fig. 23 is a fragmentary isometric view similar to Fig. 22, but depicts first
and second
planar surfaces covering the installed first and second honeycomb panels, with
a portion of the
first planar surface broken away to reveal the installed honeycomb panels;
Fig. 24 is an enlarged, isometric view of an interior portion of the wall
section depicted
in Fig. 23, wherein a portion of one stud is broken away to reveal the panel
of Figs. 5 and 6
installed between the studs;
Fig. 25 is a cross-sectional view along line 25-25 of Fig. 23 depicting the
honeycomb
panel of Figs. 2 and 3 installed in the wall section;
Fig. 26 is similar to Fig. 25, but depicts the honeycomb panel of Figs. 5 and
6 installed
in the wall section;
Fig. 27 is sitnilar to Fig. 25, but clepicts the honeycomb panel of Figs. 8
and 9 installed
in the wall section;
Fig. 28 is similar to Fig. 25, but depicts the honeycomb panel of Figs. 11 and
12
installed in the wall section;
Fig. 29 is similar to Fig. 25, but depicts the honeycomb panel of Figs. 15 and
16
installed in the wall section;
Fig. 30 is similar to Fig. 25, but depicts the honeycomb panel of Figs. 18 and
19
installed in the wall section;
Fig. 31 is a cross-sectional view of an elongated tubular cell used to form a
honeycomb
panel according to a seventh embodiment of the instant invention;
Fig. 32 is a cross-sectional view of an elongated tubular cell used to form a
honeycomb
panel according to an eighth embodiment of the instant invention;
Fig. 33 is a cross-sectional view of an elongated tubular cell used to form a
honeycomb
panel according to a ninth embodiment: of the instant invention;
5
CA 02344617 2001-04-18
Express Mail No. EK106405960US
Attorney Docket No. 4619.03
Fig. 34 is a cross-sectional view of an elongated tubular cell used to form a
honeycomb
panel according to a tenth embodiment of the instant invention;
Fig. 35 is a cross-sectional view of an elongated tubular cell used to form a
honeycomb
panel according to an eleventh embodirr-ent of the instant invention;
Fig. 36 is a cross-sectional view of an elongated tubular cell used to form a
honeycomb
panel according to a twelfth embodimenLt of the instant invention;
Fig. 37 is similar to Fig. 25, but ciepicts a honeycomb panel formed using
elongated
tubular cells according to Fig. 31 installed in the wall section;
Fig. 38 is similar to Fig. 25, but clepicts a honeycomb panel formed using
elongated
tubular cells according to Fig. 32 installed in the wall section;
Fig. 39 is similar to Fig. 25, but depicts a honeycomb panel formed using
elongated
tubular cells according to Fig. 33 installed in the wall section;
Fig. 40 is similar to Fig. 25, but depicts a honeycomb panel formed using
elongated
tubular cells according to Fig. 34 installed in the wall section;
Fig. 41 is similar to Fig. 25, but depicts a honeycomb'panel formed using
elongated
tubular cells according to Fig. 35 installed in the wall section; and
Fig. 42 is similar to Fig. 25, but depicts a honeycomb panel formed using
elongated
tubular cells according to Fig. 36 installed in the wall section;.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Several embodiments of a cellular panel 10, comprising a plurality of
elongated,
embedded tubulat cell units 12, each cell unit having at least one wall
comprising at least two
layers of material are disclosed. An advantage of this invention is that it
provides enhanced
insulation in the same dimension as a single-cell product. The multi-layered
wall or walls of
the instant invention also provide improved light control, which can be even
further enhanced
by including a black-out material as one or more of the layers of the walls.
Another advantage
of the disclosed invention is that the multi-layered walls of the disclosed
embedded tubular cell
units demonstrate enhanced pleat retention.
Referring first to Figs. 1 through 3, a first embodiment of the invention
shall be
described. Fig. 1 is a cross-sectional view of an embedded tubular cell unit
12 according to a
first embodiment of the present invention. In this embodiment, a single strip
of foldable and
6
CA 02344617 2001-04-18
Express Mail No. EK106405960US
Attorney Docket No. 4619.03
creasable material 14 is folded inside itself. The foldable and creasable
material 14 may be
made of plastic, Mylar , polyester, or some other thin film material that is
preferably capable
of retaining a crease. Alternatively, it may be a knit, woven, or non-woven
material such as a
spunbonded polyester. By folding the strip of material 14 inside itself, an
embedded tubular
cell unit 12 is thereby formed. The resulting tubular cell unit 12 has a front
side 16 and a rear
side 18.
Forming the embedded tubular c:ell unit 12 requires completion of a series of
folding
and gluing steps. In the embodiment depicted in Fig. 1, a first subordinate
crease 20 is formed
in the strip of material 14 proximate to a first free-end portion 22 of the
strip 14. In this
embodiment, the material between the first subordinate crease 20 and the first
free-end portion
22 is referred to as the first portion 24. Moving clockwise in Fig. 1 along
the material 14 from
the first free-end portion 22, the first main crease or fold 26 is encountered
next. This first
main crease 26 is the primary divider beiween the first portion 24 and the
second portion 28
along the front side 16 of the interior tubular cell. Continuing clockwise
along the material 14
from the first main crease 26, the seconci subordinate crease 30 is next
encountered. A third
subordinate crease 32 is next encountered, thereby defining the second portion
28 between the
second subordinate crease 30 and the third subordinate crease 32. This third
subordinate
crease 32 of the interior tubular cell also comprises the third subordinate
crease 32' of the
exterior tubular cell, which is further discussed below. Continuing clockwise
along the
material 14 from the third subordinate crease 32 (or 32'), the second main
crease or fold 34 is
next encountered. This second main crease or fold 34 of the interior tubular
cell also
comprises the second main crease or fo;ld 34' of the exterior tubular cell as
further discussed
below. The second main crease 34 (or 34') is the primary divider along the
rear side 18 =
between the second portion 28 of the interior tubular cell and the first
portion 24' of the
exterior tubular cell. Continuing clockwise from the second main crease 34 (or
34') along the
material 14, a fourth subordinate crease 36 is next encountered. This fourth
subordinate
crease 36 of the interior tubular cell also comprises the fourth subordinate
crease 36' of the
exterior tubular cell as further discussed below. The interior tubular cells
thus comprise four
subordinate creases 20, 30, 32, 36 and two main creases 26, 34.
The exterior tubular cell similarly comprises four subordinate creases 20',
30', 32', 36'
and two main creases 26', 34'. In this first embodiment, the third and fourth
subordinate
7
CA 02344617 2001-04-18
Express Mail No. EK106405960US
Attorney Docket No. 4619.03
creases 32, 36, respectively, and the second main crease 34 of the interior
tubular cell are the
same as the third and fourth subordinate creases 32', 36', respectively, and
the second main
crease 34' of the exterior tubular cell. 'I'laus, in the first embodiment, as
best depicted in Figs.
1 and 2, only the front side 16 of each er.nbedded tubular cell unit 12
comprises multiple layers.
In this embodiment, the rear side 18 of the two embedded cells comprises the
same section of
the strip of material 14.
It is the first and second main creases 26, 34 (or 26', 34'), respectively,
that are
primarily responsible for giving the resulting embedded tubular cell unit 12
its overall cellular
shape. This is true for each tubular cellof the family of neighboring tubular
cells comprising
each embedded tubular cell unit 12. The first and second main creases 26, 34
(or 26', 34')
tend to bias the first portion 24 (or 24) toward the second portion 28 (or
28') of each tubular
cell comprising an embedded tubular cell unit 12. Although the discussion of
this first
emboditnent and of the other embodiments refers to "pleats" or "creases," the
instant
invention does not require them. Pleats or creases may be beneficial for some
uses of the
invention and are used in this disclosure. for illustrative purposes, but are
not required and need
not be severe or well-defined.
In the first embodiment, Figs. 1 through 3, the outer su.rface of the first
portion 24 of
the interior tubular cell is affixed to the inner surface of the first portion
24' of the exterior
tubular cell by an adhesive bead 38. Clearly, more than one adhesive bead
could be used in
place of the single adhesive bead 38 depicted. The adhesive used to affix the
various parts of
an embedded tubular cell unit 12 may be, for example, heat activated or some
other type of
adhesive, or two-sided tape. An acceptable type of adhesive is aliphatic
adhesive. The outer
surface of the second portion 28 of the interior tubular cell, if affixed, is
affixed to the inner
surface of the second portion 28' of the exterior tubular cell by adhesive
beads 40 and 42.
Referring now to Figs. 2 and 3, a honeycomb panel 10 is formed by affixing
adjacent
embedded tubular cell units 12, each of which has been formed as described
above. Adjacent
embedded tubular cell units 12 are affixed with adhesive beads 44 and 46. When
the outer
surfaces of adjacent embedded tubular cell units 12 are thus adhered with
adhesive beads 44,
46, a honeycomb insulating panel 10, having a multi-layered front side 16 and
a single-layered
rear side 18 is thereby formed.
8
CA 02344617 2001-04-18
Express Mail No. EK106405960US
Attorney Docket No. 4619.03
The size of the resulting honeycomb panel 10 is a function of the cross-
sectional size of
each embedded tubular cell unit 12, the number of embedded tubular cell units
12 affixed to
form the honeycomb panel 10, and the length of each embedded tubular cell unit
12 along its
longitudinal axis. When the resultant horieycomb panel 10 (Fig. 3) is designed
to expand and
contract vertically, the length of each embedded tubular cell unit 12 defines
the width of the
resultant panel 10. The height of the pariel 10 is a function of both the
height of each
embedded tubular cell unit 12 (i.e., the distance between the first portion
24' and the second
portion 28' of the exterior tubular cell) and the number of embedded tubular
cell units 12
affixed together to form the honeycomb panel 10.
Referring now to Figs. 4 through. 6, a second embodiment of the instant
invention is
described. In this embodiment, the front side 16 of the resultant honeycomb
panel 10
comprises three layers of material, and the rear side 18 comprises two layers
of material. In
this embodiment, the honeycomb panel 10 comprises embedded tubular cell units
12 that each
comprise a family of three neighboring tubular cells. Each family member
comprises four
subordinate creases, for example, 20, 30õ 32, 36, and two main creases, for
example, 26, 34.
The second main crease 34" of the exteiior tubular cell also comprises the
main crease 34' of
the intermediate tubular cell.
In both the second embodiment: depicted in Fig. 4, as well as in the first
embodiment
depicted in Fig. 1, the outer surface of die first free-end portion 22 could
be attached to the
inner surface of the second portion 28 of the interior tubular cell. If this
were done in the first
embodiment (Figs. 1-3), for example, and the outer surface of the first free-
end portion 22
were attached to the inner surface of the second portion 28 of the interior
tubular cell by an
adhesive bead 38, both the front side 16 and the rear side 18 would comprise
two layers of
material, forming a third embodiment (see Figs. 7-9). If this were done in the
second
embodiment (Figs. 4-6), for example, both the front side 16 and the rear side
18 would
comprise three layers of material.
After reviewing the embodiments of Fig. 1 through Fig. 9, one of ordinary
skill in the
art could adjust the number of layers on the front side 16 and rear side 18 by
changing how
many times and how far the strip of material 14 is folded inside itself. For
example, by folding
the stxip of material 14 inside itself one more time in an embodiment like
those depicted in
9
CA 02344617 2001-04-18
Express Mail No. EK106405960US
Attorney Docket No. 4619.03
Figs. 4-6, a resultant cellular panel 10 would have four layers on the front
side 16 and three
layers on the rear side 18.
Referring now to Figs. 10 through 13, a fourth embodiment of the instant
invention is
discussed. In the fourth embodiment, first and second strips of material 48,
50, respectively,
are folded one inside another. The embodiment of Fig. 10 comprises a first
strip of materia148
folded into an interior precursor tubular c:ell, which is then embedded in an
exterior precursor
tubular cell formed from the second strip of material 50. The resulting
embedded precursor
tubular cell unit 12 may, before it is adhered to a next adjacent embedded
precursor tubular
cell unit 12 of a honeycomb panel 10, be opened along the first and second
inside edges (e.g.,
52, 56 and 52', 56') of each embedded precursor tubular cell, revealing the
interior of the
embedded tubular cell unit 12; hence the adjective "precursor."
In the fourth embodiment, the innermost cell is formed of the first strip of
material 48
and comprises four subordinate creases 20, 30, 32, 36 and two main creases 26,
34. In
between the first subordinate crease 20 and the fourth subordinate crease 36,
along the bottom
of the interior precursor tubular cell, is its first portion 24. Between the
second subordinate
crease 30 and the first inside edge 52 is a front second portion 54.
Similarly, between the third
subordinate crease 32 and the second inside edge 56 lies a rear second portion
58. As may be
seen clearly in Figs. 10 and 11, the inside edges 52, 56 of the front and rear
second portions
54, 58, respectively, approach one another, but do not overlap, in this
embodiment. The
exterior precursor tubular cell also comprises four subordinate creases 20',
30', 32', 36' and
two main creases 26', 34'. In addition, the exterior precursor tubular cell
has a front second
portion 54, a rear second portion 58', and first and second inside edges 52',
56', respectively.
In this embodiment the outer surface of the first portion 24 of the interior
precursor
tubular cell is affixed to the inner surface of the first portion 24' of the
exterior precursor
tubular ceII by adhesive beads 60, 62. As previously mentioned, any number of
adhesive beads
could be used to join the two precursor tubular cells to form the resultant
embedded precursor
tubular cell unit 12. The outer surface of the front second portion 54 of the
interior precursor
tubular cell is affixed by adhesive bead 64 to the inner surface of the front
second portion 54'
of the exterior precursor tubular cell adjacent the first inside edges 52, 52'
of the interior and
exterior precursor tubular cells, respectively. Similarly, the outer surface
of the rear second
portion 58 of the interior precursor tubialar cell is affixed by adhesive bead
66 to the inner
CA 02344617 2001-04-18
Express Mail No. EK106405960US
Attorney Docket No. 4619.03
surface of the rear second portion 58' of the exterior precursor tubular cell
adjacent the second
inside edges 56, 56' of the interior and exterior precursor tubular cells,
respectively. In the
fourth embodiment, therefore, both the front side 16 and the rear side 18 of
the resulting
embedded precursor tubular cell unit 12 comprise two layers of material.
Referring to Figs. 11 and 12, a honeycomb panel 10 is formed by affixing a
plurality of
embedded precursor tubular cell units 12 to one another. In this embodiment,
adhesive beads
44, 46 are applied to the outer surface of the front second portion 54' and
the rear second
portion 58', respectively, of the exterior precursor tubular cell of each
embedded precursor
tubular cell unit 12 to be joined to form a honeycomb panel 10. Subsequently,
two adjacent
embedded precursor tubular cell units 1:2 are aligned one on top of another
and pressed
together such that the adhesive beads 44, 46 on the first and second portions
54', 58' of one
embedded precursor tubular cell unit 12 adhere to the outer surface of the
first portion 24' of a
next adjacent embedded precursor tubular cell unit 12. After a stack of
embedded precursor
tubular cell units 12 have been thus affixed together, resulting in a
honeycomb insulating panel
10 of the desired size, a rigid top slat 68 (Fig. 13) may be adhered to the
top tubular cell, and a
rigid bottom slat 70 may be adhered to the bottom tubular cell. Fig. 13
depicts a complete
retractable cover 88 ready to be affixed over an architectural opening.
Referring now to Figs. 14 through 16, a fifth embod'unent is discussed. This
embodiment is most similar to the fourth embodiment just discussed. In the
fifth embodiment,
however, the first portion 24 of the interior precursor tubular cell is
neighboring the front and
rear second portions 54', 58' of the exterior precursor tubular cell.
Similarly, the front and rear
second portions 54, 58 of the interior precursor tubular cell are neighboring
the first portion
24' of the exterior precursor tubular cell. In other words, the interior
precursor tubular cell is
rotated 180 degrees about its longitudinal axis relative to the exterior
precursor tubular cell.
This differs from the fourth embodiment, depicted in Figs. 10 through 13,
wherein the first
portion 24 of one neighboring family member is affixed to the first portion
24' of a next
neighboring family member. It is clear from Fig. 14, that in the fifth
embodiment, the inner
surface of the front second portion 54' of the exterior precursor tubular cell
is affixed by
adhesive bead 64 to the outer surface of the first portion 24 of the interior
precursor tubular
cell adjacent the first subordinate crease 20 of the interior precursor
tubular cell and adjacent
the first inside edge 52' of the exterior precursor tubular cell. Likewise,
the inner surface of
11
CA 02344617 2001-04-18
Express Mail No. EK106405960US
Attorney Docket No. 4619.03
the rear second portion 58' of the exterior precursor tubuiar cell is affixed
by adhesive bead 66
to the outer surface of the first portion 24 of the interior precursor tubular
cell adjacent the
fourth subordinate crease 36 of the intejior precursor tubular cell and
adjacent the second
inside edge 56' of the exterior precursor tubular cell. Looking at the bottom
portion of Fig. 14,
the outer surface of the front second portion 54 of the interior precursor
tubular cell is affixed
by adhesive bead 60 to the inner surface of the first portion 24' of the
exterior precursor
tubular celL Similarly, the outer surface of the rear second portion 58 of the
interior precursor
tubular cell is affixed by adhesive bead 62 to the inner surface of the first
portion 24' of the
exterior precursor tubular cell. Adhesive bead 60 is adjacent first inside
edge 52 of the interior
precursor tubular cell, and adhesive bead 62 is adjacent the second inside
edge 56 of the
interior precursor tubular cell.
Referring now to Figs. 17 through 19, a sixth embodiment of the instant
invention is
discussed. In this sixth embodiment, the family of neighboring precursor
tubular cells
comprising an embedded tubular cell unit 12 consists of three members: an
interior precursor
tubular cell, an intermediate precursor tubular cell, and an exterior
precursor tubular cell.
Similar to the arrangement of the neighboring family members in the fifth
embodiment of Figs.
14 through 16, the neighboring family rnembers in the sixth embodiment are not
each aligned
with the same orientation about their longitudinal axes. For example, the
interior precursor
tubular cell is oriented with its front and rear second portions 54, 58
neighboring the first
portion 24' of the intermediate precursor tubular cell. Similarly, the front
and rear second
portions 54", 58" of the exterior precursor tubular cell are neighboring the
first portion 24' of
the intermediate precursor tubular celL Thus, just as was the case in the
fifth embodiment, in
the sixth embodiment; each precursor tubular cell in an embedded tubular cell
unit 12 is
rotated 180 degrees about its longitudinal axis relative to its next
neighboring cell or cells
within the same family of neighboring precursor tubular cells comprising a
single embedded
tubular cell unit 12.
Referring now to Fig. 17, the construction of the three-member, embedded
tubular cell
unit 12 of the sixth embodiment is discussed. The interior precursor tubular
cell is affixed to
the intermediate precursor tubular cell. The intermediate precursor tubular
cell is affixed to
both the interior precursor tubular cell and the exterior precursor tubular
cell. In the sixth
embodiment the interior precursor tubular cell is affixed to the intermediate
precursor tubular
12
CA 02344617 2001-04-18
Express Mail No. EK106405960US
Attorney Docket No. 4619.03
cell by four adhesive beads 72, 74, 76, 78. Adhesive bead 72 adheres the outer
surface of the
front second portion 54 of the interior precursor tubular cell to the inner
surface of the first
portion 24' of the intermediate precursor tubular cell. Similarly, adhesive
bead 74 adheres the
outer surface of the rear second portion 58 of the interior precursor tubular
cell to the inner
surface of the first portion 24' of the intermediate precursor tubular cell.
Adhesive bead 76
adheres the outer surface of the first portion 24 of the interior precursor
tubular cell to the
inner surface of the front second portion 54' of the intermediate precursor
tubular cell adjacent
the first inside edge 52' of the intermediate precursor tubular cell. Adhesive
bead 78 adheres
the outer surface of the first portion 24 of the interior precursor tubular
cell to the inner
surface of the rear second portion 58' of the intermediate precursor tubular
cell adjacent the
second inside edge 56' of the intermediate precursor tubular cell.
The combination of the interior precursor tubular cell and the intermediate
precursor
tubular cell is next affixed to the exterior precursor tubular cell by
adhesive beads 80, 82, 84,
86. Adhesive bead 80 adheres the outer surface of the first portion 24' of the
intermediate
precursor tubular cell to the inner surface of the front second portion 54" of
the exterior
precursor tubular cell. Similarly, adhesive bead 82 adheres the outer surface
of the first portion
24' of the intermediate precursor tubulax cell to the inner surface of the
rear second portion
58" of the exterior precursor tubular cell. Adhesive bead 84 adheres the outer
surface of the
front second portion 54' of the intermediate precursor tubular cell to the
inner surface of the
first portion 24" of the exterior precursor tubular cell. Finally, adhesive
bead 86 adheres the
outer surface of the rear second portior- 58' of the intermediate precursor
tubular cell to the
inner surface of the first portion 24" of the exterior precursor tubular cell.
The resultant
embedded tubular cell unit 12 has three layers of material on both its front
side 16 and its rear
side 18.
Referring now to Figs. 18 and 19, a honeycomb insulating pane110 is depicted
that has
been made by adhering together embedded tubular cell units 12 according to the
sixth
embodiment. The cellular panel 10 depicted in Figs. 18 and 19 is formed by
adhering adjacent
embedded tubular cell units 12 to each other with adhesive beads 44, 46. For
example,
referring to Fig. 18, adhesive bead 44 is applied to the outer surface of the
exterior precursor
tubular cell of the bottom embedded tubular cell unit 12 near its front second
portion 54".
Adhesive bead 46 is applied to the outer surface of the exterior precursor
tubular cell of the
13
CA 02344617 2001-04-18
Express Mail No. EK106405960US
At:torney Docket No. 4619.03
same bottom embedded tubular cell unit: 12 near its rear second portion 58".
With beads 44
and 46 in place, the outer surface of the first portion 24" of the exterior
precursor tubular cell
of the top embedded tubular cell unit 12, in Fig. 18 is then pressed against
the adhesive beads
44 and 46 of the bottom embedded tubiilar cell unit 12. Although only two
embedded tubular
cell units 12 are joined in the honeycomb insulating panel 10 depicted in
Figs. 18 and 19, any
number of embedded tubular cell units 12 could be affixed together to create a
honeycomb
panel 10 of any desired size.
In the fifth embodiment (Figs. 14-16) and sixth embodiment (Figs. 17-19), an
individual embedded tubular cell units 12 may not be opened to reveal its
interior, even before
it is affixed to an adjacent embedded tubular cell units 12 to form a
resultant honeycomb
insulating panel 10. The alternating configuration of these embodiments,
wherein the
orientation of each tubular cell in the embedded tubular cell unit 12 is
rotated 180 degrees
about its longitudinal axis in relation to its neighbor or neighbors, prevents
being able to open
the embedded tubular cell unit 12 along a line parallel to its longitudinal
axis. In other words,
in the fifth and sixth embodiments, evei.y other tubular cell of a particular
family of
neighboring embedded tubular cells is rotated 180 degrees about its
longitudinal axis. This
provides additional structural integrity to each individual embedded tubular
cell unit 12.
Figs. 20-22 depict an embodiment wherein one or more of the honeycomb panels
10
formed according to the present invention is used in a cavity, e.g., a wall
section 90. Fig. 20 is
an isometric view of the wall section 90. The wall section 90 is constructed
from a bottom or
lower plate 92, a top or upper plate 94, a plurality of sides or studs 96
extending between and
joining the lower plate 92 and the uppe;r plate 94, one or more honeycomb
panels 10 mounted
between the studs and plates, and at least a first planar surface 98. The
first planar surface 98
may, for example, form an inner wall of" drywall, plasterboard, paneling, or
glass. When at least
two studs 96 extend between and join the upper plate 94 and the lower plate
92, that creates a
substantially rectangular frame 102 defining a cavity 104 into which one or
more expandable
and contractible honeycomb panels 10 may be inserted. The first planar surface
98, which is
attached to a first side of the frame 102 (e.g., by nailing, screwing, or
gluing), gives the frame
102 structural support and defines a bottom for the cavity 104.
= A first honeycomb panel 10' is depicted in Fig. 20 installed between the
rightmost stud
and the center stud of the wall section, and extending between the upper plate
and the lower
14
CA 02344617 2001-04-18
Express Mail No. EK106405960US
Attorney Docket No. 4619.03
plate. More than one honeycomb panel could be used in place of the single
first honeycomb
panel 10' depicted in Fig. 20 if desired. The first honeycomb panel 10' is
affixed to the bottom
surface of the upper plate 94 using known procedures (e.g., gluing or
stapling). As depicted in
Fig. 20, the first honeycomb panel 10 is fiilly extended. A second honeycomb
panel 10" is
shown in a retracted or collapsed position, but poised for installation
between the leftmost and
center studs 96 depicted in Fig. 20.
Fig. 21 is similar to Fig. 20, but the second honeycomb panel 10" has been
extended in
preparation for installation into the wall section 90. In Fig. 22, the second
honeycomb panel
10" is shown installed between the leftmost and center studs 96 of the wall
section 90. Again,
the single second honeycomb panel 10" depicted in Figs. 20-22 could be
replaced by multiple
honeycomb panel sections. For exampleõ if a horizontal support or other item
interrupted the
gap between the upper and lower plates 94, 92, respectively, and the left and
center studs 96, a
two-piece second honeycomb panel may be used in place of the single-piece
second
honeycomb panel 10" depicted in Figs. 20-22.
Fig. 23 is similar to Fig. 22, but depicts both the first planar surface 98
and a second
planar surface 100 installed as part of the wall section 90. The second planar
surface 100,
which is attached to a second side of the frame 102 (e.g., by nailing,
screwing, or gluing), gives
the frame 102 structural support and defines a top for the cavity 104 (Fig.
20). The second
planar surface 100 could comprise, for example, drywall, plasterboard,
paneling, or glass like
the first planar surface 98, or the second planar surface 100 could comprise,
for example,
siding or brick. As shown in Fig. 23, each of the first and second planar
surfaces comprises
more than one piece. A single sheet of rnaterial could, however, comprise each
planar surface.
In Fig. 23, a portion of the first planar surface 98 has been broken away to
clearly depict the
first honeycomb panel 10' and the second honeycomb panel 10" installed within
the wall
section 90 between the studs, plates, and. planar surfaces.
Fig. 24 is an enlarged view of an interior part of the wall section 90
depicted in, for
example, Fig. 23. In Fig. 24, a portion of one stud 96 has been broken away to
demonstrate
that the honeycomb panel 10' mounted between the studs is constructed from the
panel
material depicted to best advantage in Figs. 5 and 6. The panel 10', however,
could be
constructed according to any of the disctosed embodiments as shown, for
example, in Figs. 25-
30 and 37-42. Fig. 25 is a cross-sectional view along line 25-25 of Fig. 23
and depicts the
CA 02344617 2001-04-18
Express Mail No. EK106405960US
Attorney Docket No. 4619.03
panel of Figs. 2 and 3 installed in the wall section 90. Fig. 26 is similar to
Fig. 25, but depicts
the panel of Figs. 5 and 6 installed in the wall section. Fig. 27 is similar
to Fig. 25, but depicts
the panel of Figs. 8 and 9 installed in the wall section. Fig. 28 is similar
to Fig. 25, but depicts
the panel of Figs. 11 and 12 installed in the wall section. Fig. 29 is similar
to Fig. 25, but
depicts the panel of Figs. 15 and 16 insta.lled in the wall section. Fig. 30
is similar to Fig. 25,
but depicts the panel of Figs. 18 and 19 installed in the wall section.
Figs. 31-36 depict six additional alternative embodiments for the embedded
tubular cell
unit 12. Fig. 31 depicts a seventh embociiment of the embedded tubular cell
unit. This
seventh embodiment is most similar to the first embodiment as depicted in Fig.
1. In the
seventh embodiment depicted in Fig. 31, however, the material along the rear
side 18 of the
embedded tubular cell unit 12 between the third subordinate creases 32, 32'
and the fourth
subordinate creases, 36, 36' has been shortened, and the second main creases
34, 34' (Fig. 1)
have been removed.
The embodiment of the embedded tubular cell unit 12 depicted in Fig. 32 is
most
similar to the second embodiment depicted in Fig. 4. When the eighth
embodiment depicted
in Fig. 32 is compared with the second embodiment depicted in Fig. 4, however,
the second
main creases 34, 34', 34" are absent in the eighth embod'unent, and the
material along the rear
side 18 has been shortened in the eighth embodiment.
Fig. 33 depicts the ninth embodiment of the embedded tubular cell unit 12 of
the
present invention. This ninth embodiment is most similar to the third
embodiment, which is
depicted in Figs. 7-9. Comparing Fig. 3:3 to Fig. 7, the ninth embodiment is
different from the
third embodiment in that the main creases 34, 34' along the rear side 18 of
the embedded
tubular cell unit 12 are absent in the ninth embodiment. In addition, the
material along the
rear side 18 has been shortened in the ninth embodiment.
Fig. 34 depicts a tenth embodiment of the embedded tubular cell unit 12
according to
the present invention. This tenth embodiment is most similar to the fourth
embod'unent
depicted in Figs. 10-12. Comparing Fig. 34 to Fig. 10, in the tenth embodiment
the second
main creases 34, 34' (Fig. 10) that are present in the fourth embodiment are
absent from the
tenth embodiment since the material along the rear side 18 of the embedded
tubular cell unit
12 has been shortened.
16
CA 02344617 2001-04-18
Express Mail No. EK106405960US
Attorney Docket No. 4619.03
Fig. 35 depicts the eleventh embodiment of the embedded tubular cell unit 12
according to the present invention. The eleventh embodiment is most similar to
the fifth
embodiment, which is depicted in Figs. 14-16. Comparing Fig. 35 to Fig. 14, it
is apparent
that the material along the rear side 18 of' the embedded tubular cell unit 12
is shorter in the
eleventh embodiment than it is in the fifth embodiment. Also, the main creases
34, 34' of the
fifth embodiment (Fig. 14) are absent from the eleventh embodiment (Fig. 35).
Fig. 36 depicts a twelfth embodiment of the embedded tubular cell unit
according to
the present invention. This twelfth embodiment is most similar to the sixth
embodiment
depicted in Figs. 17-19. The second main creases of the interior,
intermediate, and exterior
precursor tubular ceIls 34, 34', 34", respectively, are absent in the twelfth
embodiment, and the
material along the rear side 18 of the embedded tubular cell unit 12 has been
shortened in the
twelfth embodiment.
The embedded tubular cell unit 1.2 depicted in Figs. 31-36 are otherwise
constructed in
the same manner as the corresponding embedded tubular cell unit 12 as depicted
in Figs. 1, 4,
7, 10, 14, and 17, respectively.
Figs. 37-42 correspond to Figs. 31-36, respectively, and to Figs. 25-30,
respectively.
For example, Fig. 37 is similar to Fig. 25, but depicts in the wall section 90
a honeycomb panel
constructed from embedded tubular cell units 12 having the cross-section
depicted in Fig. 31.
Although several embodiments of this invention have been described above, it
will be
apparent to those skilled in the art that numerous alterations may be made
without departing
from the spirit or scope of this invention. For example, the single strip of
material 14 that is
rolled inside itself to form the embedded tubular cell units 12 of the first,
second, third,
seventh, eighth, and ninth embodiments could be roLed inside itself any number
of times to
provide the desired light blocking or insulating capabilities. Similarly, the
number of tubular
cells in a family of neighboring tubular cells comprising an embedded tubular
cell unit 12 can
be altered to achieve desired light blocking or insulating capabilities. An
important feature of
this invention is that a multi-layered cellular panel may be formed that has
superior insulating
or light-block.ing capabilities when compared to a single-layered honeycomb
panel, but takes
up approximately the same volume. This characteristic feature could also be
achieved by using
multiple sheets of material to replace a single sheet in the above
embodiments. For example,
in the fourth embodiment (Figs. 10-12)õ the second strip of material 50 could
be cut along its
17
CA 02344617 2001-04-18
Express Mail No. EK106405960US
Attorney Docket No. 4619.03
first portion 24', between adhesive beads 60 and 62, into two separate sheets
of material.
One resulting separate sheet could be affixed to the first strip of material
48 by adhesive beads
60 and 64, and the other resulting sheet could be affixed to the first strip
of material 48 by
adhesive beads 62 and 66. It is intended that the resulting embodiments,
though not
specifically depicted and described hereivn, would fall within the scope of
the appended claims.
Another example of an embodiment intended to be covered by the appended claims
is
formed by slightly modifying the first embodiment (Figs. 1-3). For example, a
longitudinal cut
could be made in the first portion 24' of the exterior tubular cell just to
the right of adhesive
bead 38 in Fig. 1. Then, the remaining part of first portion 24' adjacent the
fourth subordinate
crease 36, 36', could be affixed to the first free-end portion 22. Although
each resulting
embedded tubular cell 12 would no longer comprise a single strip of material
14, the resulting
embedded tubular cell would resemble ihe first embodiment depicted and
described above,
with a multi-layered front side. The p6nary difference being that it would
comprise two
sheets of material rather than one.
If the multi-layer embedded tubular cell units 12 are pleated or creased as
shown in the
above embodiments, then each embedded tubular cell unit 12 of the resulting
honeycomb
insulating panel 10 will have superior pleat or crease retaining properties
since more layers of
material are supporting the weight of the honeycomb insulating panel 10. It
will be
appreciated, however, that although a pleat or crease may be preferred, it is
not necessary; and
the scope of the invention should be interpreted to incorporate uncreased
structures and
partially creased structures. It will also be appreciated that while a
hexagonal structure is
shown, any shape of structure is conternplated.
Although the honeycomb panel 10 depicted in Figs. 2, 3, 5, 6, 8, 9, 11, 12,
13, 15, 16,
18, and 19 is oriented such that the embedded tubular cell units 12 extend
horizontally (i.e.,
have their longitudinal axes extending horizontally), the honeycomb panel 10
could be hung
such that the embedded tubular cells were oriented vertically without
departing from the scope
of this invention. In a vertical configutation, the honeycomb panel 10 would
expand and
contract horizontaIly rather than vertically.
It is intended, therefore, that all matter contained in the above description
and shown
in the accompanying drawings shall be interpreted as illustrative only and not
limiting.
18
