Lightweight shielded panel system including acoustical shielding

Abstract

A composite panel for a lightweight shielded panel system. Such panel includes a honeycomb type core member formed from a first predetermined material and having each of a first predetermined thickness, a first predetermined width and a first predetermined length. A skin layer is formed from a second predetermined material and disposed on each face of such honeycomb type core member. The has each of a second predetermined thickness, a second predetermined width and a second predetermined length. There is also an outer perimeter frame formed from a third predetermined material and which has each of a third predetermined thickness, a third predetermined width and a third predetermined length.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application is closely related to and claims priority from U.S. Provisional Patent Application Ser. No. 60/680,748 filed May 13, 2006.

FIELD OF THE INVENTION

The present invention relates, in general, to a panel particularly designed for shielding radio frequencies and, more particularly, this invention relates to a lightweight modular type panel for a shielding system which has high performance and acoustical shielding characteristics incorporated therein.

BACKGROUND OF THE INVENTION

Prior to the conception and development of the present invention, it has been known in the prior art to provide shielding of enclosures against detrimental radio frequencies. Most of the prior art type panels which are known to applicant have incorporated in them various materials some of which contain wood products.

Additionally, most of these prior art type panels that are utilized in making a radio frequency shielded enclosure are relatively heavy and generally are not well designed from an acoustical standpoint.

One panel applicant is aware of is disclosed in U.S. Pat. No. 5,534,663 issued to Rivers et al. which teaches an electrically shielded enclosure for electrical components therein. The teachings of this patent are incorporated herein by reference thereto.

Applicant is also aware of U.S. Pat. No. 6,831,224 issued to Koivusilta which teaches a one-piece shielding casing for shielding electronic circuits and devices. The teachings of this reference are also incorporated herein by reference thereto.

Another composite of which applicant is aware is U.S. Pat. No. 4,599,255 issued to Angling et al. which teaches another composite material for shielding. The teachings of this reference are further incorporated herein by reference thereto.

SUMMARY OF THE INVENTION

The present invention provides a composite panel structure for electrically shielding against radio frequency and which also exhibits improved acoustical capabilities. The composite panel is a component in a lightweight shielded panel system. Such composite panel includes a honeycomb type core member formed from a first predetermined material and having each of a first predetermined thickness, a first predetermined width and a first predetermined length. There is a metallic skin layer formed from a second predetermined material disposed on each face of such honeycomb type core member. Such skin layer has each of a second predetermined thickness, a second predetermined width and a second predetermined length. Additionally, there is an outer perimeter frame formed from a third predetermined material. Such outer perimeter has each of a third predetermined thickness, a third predetermined width and a third predetermined length.

OBJECTS OF THE INVENTION

It is, therefore, one of the primary objects of the present invention to provide a composite type panel for use in constructing an electrically shielded enclosure.

Another object of the present invention is to provide a composite type panel for use in constructing a radio frequency shielded enclosure.

Still another object of the present invention is to provide a composite type panel for use in constructing a shielded enclosure having improved acoustical characteristics.

Yet another object of the present invention is to provide a composite type panel for use in constructing a shielded enclosure which is relatively lightweight.

A further object of the present invention is to provide a composite type panel for use in constructing a shielded enclosure which will exhibit relatively high performance characteristics.

In addition to the several objects and advantages of the present invention which have been described with some degree of specificity above, it should be noted that various additional objects and advantages of the present invention will become more readily apparent to those persons who are skilled in the relevant art from the following more detailed description, particularly, when such description is taken in conjunction with the attached drawing Figure and with the appended claims.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a cross-sectional view of a presently preferred embodiment of a panel constructed in accordance with the invention; and

FIG. 2 is an exploded view of the panel illustrated in FIG. 1.

BRIEF DESCRIPTION OF A PRESENTLY PREFERRED AND VARIOUS ALTERNATIVE EMBODIMENTS OF THE INVENTION

Prior to proceeding to the more detailed description of the present invention, it should be noted that, for the sake of clarity and understanding, identical components which have identical functions have been identified with identical reference numerals throughout the different views illustrated in the drawing Figures.

Reference is now made to the drawing Figures wherein there is illustrated a presently preferred embodiment of a composite, generally designated 10, for use as a relatively lightweight shielding material to construct an enclosure which is shielded against undesirable radio frequencies and which can be constructed to exhibit excellent acoustical characteristics.

Such composite 10 includes a honeycomb type core member 12 formed from a first predetermined material. The honeycomb type core member 12 has each of a first predetermined thickness, a first predetermined width and a first predetermined length.

In the presently preferred embodiment of the invention, the first predetermined material such honeycomb type core member 12 is formed from is selected from the group consisting of aluminum, polypropylene and mylar. With aluminum being the most preferred material. Also in this embodiment of the invention of the composite panel 10 the first predetermined thickness of the honeycomb type core member 12 is between about 0.5 inch and about 4.0 inches. It is more preferred for this first predetermined thickness to be about 0.625 inch.

There is a skin layer 14 formed from a second predetermined material disposed on each face 16 of such honeycomb type core member 12. The skin layer 14 includes each of a second predetermined thickness, a second predetermined width and a second predetermined length.

The second predetermined material that such skin layer 14, is formed from in the presently preferred embodiment of the invention is selected from the group consisting of aluminum and plastic. Which of these two particular materials will be selected is primarily dependent on the end use of the composite panel 10. However, it will normally be aluminum for most applications presently contemplated.

Such second predetermined thickness is between about 0.018 inch and about 0.125 inch in the broad sense of the invention and in the most preferred embodiment such second predetermined thickness is between about 0.025 inch and about 0.05 inch.

An outer perimeter frame 18 is formed from a third predetermined material. Outer perimeter frame 18 has each of a third predetermined thickness, a third predetermined width and a third predetermined length.

According to the presently preferred embodiment of the invention, the third predetermined material of such outer perimeter frame 18 is aluminum.

The composite panel 10 for a lightweight shielded panel system can also be designed to exhibit improved acoustical characteristics. In this embodiment of the invention such composite panel 10 will further include a predetermined acoustic dampening material 20 disposed on an outer surface 22 of at least one skin layer 14. Preferably such composite panel 10 will include a layer of such predetermined acoustic dampening material 20 disposed on the outer surface 22 of each one of such skin layers 14. Further it is presently preferred that such predetermined acoustic dampening material will be a mass loaded vinyl. It is additionally preferred that such mass loaded vinyl is applied to each such outer surface 22 of such skin layer 14 in an amount of between about 0.5 and about 2.0 lbs. per square foot.

In the presently most preferred embodiment of the invention, the composite panel 10 for a lightweight shielded panel system will further include an outer skin layer 24 formed from a fifth predetermined material disposed over such predetermined acoustic dampening material 20. The predetermined acoustic dampening material 20 has a fifth predetermined thickness. Preferably the fifth predetermined material of such outer skin layer 24 is metal. The most preferred metal for such outer skin layer 24 is galvanized sheet steel. The fifth predetermined thickness of such outer skin layer is preferably between about 12 gauge and 28 gauge.

While in accordance with the patent statutes both a presently preferred and various alternative embodiments of the invention have been described above in sufficient detail to enable anyone skilled in the relevant art to make and use the same, it should be understood that various additional modifications and alterations can be made without departing from either the spirit of the invention or the scope of the appended claims.

Claims

1. A composite panel for a lightweight shielded panel system, said composite panel comprising:

(a) a honeycomb type core member formed from a first predetermined material and having each of a first predetermined thickness, a first predetermined width and a first predetermined length;

(b) a skin layer formed from a second predetermined material disposed on each face of said honeycomb type core member and having each of a second predetermined thickness, a second predetermined width and a second predetermined length; and

(c) an outer perimeter frame formed from a third predetermined material and having each of a third predetermined thickness, a third predetermined width and a third predetermined length.

2. A composite panel for a lightweight shielded panel system, according to claim 1, wherein said first predetermined material of said honeycomb type core member is selected from the group consisting of aluminum, polypropylene and mylar.

3. A composite panel for a lightweight shielded panel system, according to claim 1, wherein said second predetermined material of said skin layer is selected from the group consisting of aluminum and plastic.

4. A composite panel for a lightweight shielded panel system, according to claim 1, wherein said second predetermined material is aluminum.

5. A composite panel for a lightweight shielded panel system, according to claim 1, wherein said third predetermined material of said outer perimeter frame is aluminum.

6. A composite panel for a lightweight shielded panel system, according to claim 1, wherein said composite panel exhibits acoustical characteristics and further includes a predetermined acoustic dampening material disposed on an outer surface of at least one said skin layer.

7. A composite panel for a lightweight shielded panel system, according to claim 6, wherein said predetermined acoustic dampening material is mass loaded vinyl.

8. A composite panel for a lightweight shielded panel system, according to claim 7, wherein said mass loaded vinyl is applied to said each outer surface of said skin layer in an amount of between about 0.5 and about 2.0 lbs. per square foot.

9. A composite panel for a lightweight shielded panel system, according to claim 6, wherein said composite panel includes said predetermined acoustic dampening material disposed on each outer surface of each said skin layer.

10. A composite panel for a lightweight shielded panel system, according to claim 6, wherein said composite panel further includes an outer skin layer formed from a fifth predetermined material disposed over said predetermined acoustic dampening material and having a fifth predetermined thickness.

11. A composite panel for a lightweight shielded panel system, according to claim 1, wherein said fifth predetermined material of said outer skin layer is metal.

12. A composite panel for a lightweight shielded panel system, according to claim 11, wherein said metal is galvanized sheet steel.

13. A composite panel for a lightweight shielded panel system, according to claim 12, wherein said fifth predetermined thickness is between about 12 gauge and 28 gauge.

14. A composite panel for a lightweight shielded panel system, according to claim 1, wherein said first predetermined thickness is between about 0.5 inch and about 4.0 inches.

15. A composite panel for a lightweight shielded panel system, according to claim 1, wherein said first predetermined thickness is preferably about 0.625 inch.

16. A composite panel for a lightweight shielded panel system, according to claim 1, wherein said second predetermined thickness is between about 0.018 inch and about 0.125 inch.

17. A composite panel for a lightweight shielded panel system, according to claim 16, wherein said second predetermined thickness is between about 0.025 inch and about 0.05 inch.