Multiwall sheet and methods of using the same

Patent metadata

Field	Value
Publication number	US-11041307-B2
Application number	US-201716471836-A
Country	US
Kind code	B2
Filing date	Dec 27, 2017
Priority date	Dec 30, 2016
Publication date	Jun 22, 2021
Grant date	Jun 22, 2021

Abstract

In one embodiment, a multiwall sheet can comprise: a first wall; a second wall; an intermediate wall disposed between the first wall and the second wall; a first set of ribs disposed between the first wall and the intermediate wall; a second set of ribs disposed between the second wall and the intermediate wall; a cavity disposed between adjacent ribs; wherein the multiwall sheet is configured to expand and/or collapse when a mechanical force (preferably shear force) is applied to the intermediate wall. Preferably the multiwall sheet has a flexural rigidity of greater than or equal to 10 N/mm.

First claim

What is claimed is:

1. A multiwall sheet, comprising:
a first wall;
a second wall;
an intermediate wall disposed between the first wall and the second wall;
a first set of ribs disposed between the first wall and the intermediate wall;
a second set of ribs disposed between the second wall and the intermediate wall; and
a cavity disposed between adjacent ribs of the first set of ribs and the second set of ribs;
wherein the multiwall sheet is configured to expand and/or collapse when a mechanical force is applied to the intermediate wall; and
further comprising a side wall configured to attach to the multiwall sheet after an expansion and/or collapse, wherein the side wall extends from the first wall to the second wall and is configured to interlock with the locking segment.

2. The multiwall sheet of claim 1 , wherein the cavity is configured to receive a filler material, wherein the filler material comprises sand, liquid, polyurethane foam, fibrous insulation, or a combination thereof.

3. The multiwall sheet of claim 2 , wherein the cavity comprises a plurality of cavities and adjacent cavities of the plurality of cavities are occupied by different filler materials.

4. The multiwall sheet of claim 1 , wherein the multiwall sheet comprises polycarbonate, thermoplastic, or a combination thereof.

5. The multiwall sheet of claim 1 , wherein the multiwall sheet is configured to re-expand after an initial collapse and/or re-collapse after an initial expansion when a mechanical force is applied to the intermediate wall.

6. The multiwall sheet of claim 1 , wherein the first set of ribs and the second set of ribs are reconfigurable.

7. The multiwall sheet of claim 1 , wherein the first set of ribs is symmetrical as compared with the second set of ribs.

8. The multiwall sheet of claim 1 , wherein the first set of ribs is asymmetrical as compared with the second set of ribs.

9. The multiwall sheet of claim 1 , wherein a space between adjacent ribs of the first set of ribs and second set of ribs is greater than or equal to a length of the adjacent ribs.

10. The multiwall sheet of claim 1 , wherein a thickness of the first wall and/or second wall is greater than a thickness of a rib of the first and second sets of ribs.

11. The multiwall sheet of claim 10 , wherein the thickness of the first wall and/or second wall is 1.1 to 50 times greater than the thickness of a rib of the first and second sets of ribs.

12. The multiwall sheet of any of claim 1 , wherein a thickness of the intermediate wall is greater than a thickness of the first wall and/or second wall.

13. The multiwall sheet of claim 1 , wherein a thickness of the multiwall sheet when maximally expanded is 5 to 10 times greater than a thickness of the multiwall sheet when fully collapsed.

14. The multiwall sheet of claim 1 , wherein the multiwall sheet is configured to function as a roof, cover, wall, panel, floor, window glazing, thermal insulation, structural member, acoustical barrier, electromagnetic shield or a combination thereof.

15. A method of forming a multiwall sheet, comprising:
extruding the multiwall sheet as a single unitary structure;
wherein the multiwall sheet comprises a first wall, a second wall, an intermediate wall disposed between the first wall and the second wall, a first set of ribs disposed between the first wall and the intermediate wall, a second set of ribs disposed between the second wall and the intermediate wall, and a cavity disposed between adjacent ribs of the first set of ribs and the second set of ribs, wherein the multiwall sheet is configured to expand and/or collapse when a mechanical force is applied to the first wall, the second wall, the intermediate wall, or a combination thereof, and further comprising a side wall configured to attach to the multiwall sheet after an expansion and/or collapse, wherein the side wall extends from the first wall to the second wall and is configured to interlock with the locking segment, and wherein a flexural rigidity of the multiwall sheet is greater than or equal to 10 N/mm.

16. The method of claim 15 , wherein the first set of ribs and the second set of ribs are extruded at a 40 to 50 degree angle relative to the intermediate wall.

17. The method of claim 15 , further comprising injecting expanding foam into the cavity of the multiwall sheet.

Assignees

• Sabic Global Technologies Bv

Inventors

• Davis Michael J
• Thiagarajan Chinniah

Classifications

• B29K2069/00

  Use of PC, i.e. polycarbonates {or derivatives thereof}, as moulding material · CPC title

• E04B1/80

  slab-shaped · CPC title

• E04B1/82

  specifically with respect to sound only ({of floors or ceilings E04B9/001;} noise damping in ducts or channels E04F17/00; noise damping in general G10K11/16) · CPC title

• E04B9/0414

  being foldable, curvable or rollable · CPC title

• E04C2/543

  Hollow multi-walled panels with integrated webs · CPC title