Wallboard panel

Abstract

The instant invention is directed to a wallboard panel which is made from new or recycled paper. The panel comprises a pair of sheet members which are parallel in alignment and a honeycomb core sandwiched between the sheet members. The inner surfaces of the sheet members are coated with an adhesive material and the honeycomb core is impressed into the adhesive layers. The honeycomb core is manufactured by a novel process. The sheet members and honeycomb core can be coated with a phenolic resin and/or a fire retardant material. The wallboard panel can also include insulation and/or fire-retardant material disposed within the hollow honeycomb core.

1 . A process for forming a honeycomb structure comprising:
 continuously removing sheets of paper from individual rolls of paper;   applying a plurality of bands of glue to one side of each sheet of paper;   each band of glue being relatively short compared to the length of the roll of paper and extending substantially the entire width of the sheet of paper;   spacing the bands of glue an equal distance from each other;   arranging the sheets of paper in a stacked relationship on top of each other;   the bands of glue on adjacent sheets being spaced apart in a staggered relationship such that the bands of glue on one sheet are spaced midway between the bands of glue on the adjacent sheet;   cutting the sheets of paper into a plurality of strips;   attaching the strips in a stacked relationship whereby a plurality of stacked strips forms a section which can be expanded;   expanding the strips to form a honeycomb structure.   
     
     
         2 . A process for forming a wallboard panel comprising:
 forming a pair of rigid sheet members from paper;   aligning said sheet members in parallel and in spaced relationship to each other;   forming a honeycomb core by the process of  claim 1 ; and   attaching the honeycomb core in between said pair of rigid sheet members.   
     
     
         3 . The process of  claim 2 , further including coating the inner surfaces of each of said sheet members with an adhesive; and
 impressing said honeycomb core into said adhesive layers.   
     
     
         4 . The process of  claim 2 , further including filling a plurality of cells of said honeycomb core with a solid material. 
     
     
         5 . The process of  claim 2 , further including impregnating said honeycomb core with a phenolic resin. 
     
     
         6 . The process of  claim 2 , further including impregnating said rigid sheet members with a phenolic resin. 
     
     
         7 . The process of  claim 2 , further including impregnating said rigid sheet members with plaster. 
     
     
         8 . The process of  claim 2 , further including filing a plurality of cells of said honeycomb core with an insulating material. 
     
     
         9 . The process of  claim 2 , further including filing a plurality of cells of said honeycomb core with a fire retardant material. 
     
     
         10 . The process of  claim 4 , wherein said plurality of cells of said honeycomb core comprise the cells immediately adjacent the peripheral edges of said wallboard panel. 
     
     
         11 . The process of  claim 2 , wherein the thickness of said wallboard panel adjacent the longitudinal edges is reduced.