Composite core with reinforced plastic strips and method thereof

Patent metadata

Field	Value
Publication number	US-11059259-B2
Application number	US-201715818033-A
Country	US
Kind code	B2
Filing date	Nov 20, 2017
Priority date	Nov 21, 2016
Publication date	Jul 13, 2021
Grant date	Jul 13, 2021

Abstract

Some embodiments provide a core member for a composite panel that includes a hollow cell network structure, such as a honeycomb arrangement for example, and reinforced plastic strips positioned on a portion of the continuous honeycomb structure. The honeycomb structure and the solid plastic strips may be fastened together using heat and/or pressure applications. Additionally, the method for the production of the core member is provided.

First claim

I claim:

1. A composite panel, comprising:
an inner sheet and an outer sheet disposed opposite of the inner sheet, and
a core member positioned between the inner and outer sheets, the core member comprising a continuous material including a) a partially hollow structure and b) a gap section, the gap section extending between a first end and a second end of the partially hollow structure and having a shorter height than the partially hollow structure to create a gap, wherein the partially hollow structure has a lower volumetric mass density than the gap section as a result of the gap section being formed by an interruption during a vacuum forming process of the core member or compressing a portion of the partially hollow structure.

2. The composite panel of claim 1 further including a reinforced material, wherein the reinforced material is designed to be inserted into the gap and coupled to the partially hollow structure.

3. The composite panel of claim 2 , wherein the reinforced material is coupled to the partially hollow structure adjacent the first end thereof.

4. The composite panel of claim 3 , the reinforced material is coupled to the partially hollow structure adjacent the second end thereof.

5. The composite panel of claim 2 , wherein the partially hollow structure is at least 80% of a volume of the core member.

6. The composite panel of claim 5 , wherein the partially hollow structure is at least 95% of the volume of the core member.

7. The composite panel of claim 2 , wherein the reinforced material is selected from the group consisting of high density polyethylene, high density polypropylene, low density polyethylene, polyethylene terephthalate, polypropylene, and combinations thereof.

8. The composite panel of claim 2 , wherein the composite panel has a length dimension ranging between about 2.5 meters to about 3.5 meters.

9. The composite panel of claim 8 , wherein the composite panel has a width dimension ranging between about 1 meter to about 2 meters.

10. The composite panel of claim 2 , wherein the partially hollow structure is provided as a network of hexagonal cells.

11. The composite panel of claim 2 , wherein the reinforced material is designed to be welded to the partially hollow structure.

12. The composite panel of claim 2 , wherein the partially hollow structure has a lower volumetric mass density than the reinforced material.

13. The composite panel of claim 1 , wherein the partially hollow structure is interrupted by a plurality of gap sections.

14. The composite panel of claim 1 , wherein the gap section is created by interrupting the vacuum forming process.

15. The composite panel of claim 2 , wherein the reinforced material is a solid material that fills the gap.

Assignees

• Wabash National Lp

Inventors

• Baker Leonard W

Classifications

• B29D24/005

  the structure having joined ribs, e.g. honeycomb · CPC title

• B29D99/0089

  Producing honeycomb structures (consisting of porous ceramic ware C04B38/0006) · CPC title

• B32B37/1018 Primary

  using only vacuum · CPC title

• B29C66/7254

  honeycomb structures · CPC title

• B29C69/00

  Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore {(B29C48/001 takes precedence)} · CPC title