Method of making sandwich-like product starting with extruded profile

Patent metadata

Field	Value
Publication number	US-9550318-B2
Application number	US-201414300875-A
Country	US
Kind code	B2
Filing date	Jun 10, 2014
Priority date	Dec 5, 2006
Publication date	Jan 24, 2017
Grant date	Jan 24, 2017

Abstract

A process of making a multi-layered product from an extruded sheet or web of material ( 42 ) having parallel upper and lower walls ( 130 ) and a plurality of spacers ( 134 ) extending between the upper and lower walls ( 130 ) is provided. Portions of the extruded web or extrudate ( 42 ) are removed in selected areas. The lightened web is then folded. Outer skins are then applied to the folded web. The extrudate ( 42 ) is formed into a product ( 10 ) having a plurality of cells ( 14 ). The cells ( 14 ) may have one or more openings ( 34 ), allowing access to an interior of the cell ( 14 ) and reducing the weight of the product ( 10 ).

First claim

I claim:

1. A process of making a sandwich-like product, said process comprising, in any desired order:
providing an extruded web having spaced upper and lower walls and a plurality of spacers extending between the upper and lower walls, the spacers being spaced from each other to define a plurality of flutes;
removing portions of the extruded web using multiple movable tools to create a treated web having lightened areas transversely extending from one side edge of the extruded web to the other side edge of the extruded web;
folding the treated web such that upper and lower walls of the untreated regions of the treated web become sidewalls of a plurality of cells arranged in rows of a core of the sandwich-like product;
applying outer skins to tops and bottoms of the cells of the core to create a multi-layered web.

2. The process of claim 1 further comprising cutting the multi-layered web.

3. The process of claim 1 wherein removing portions of the extruded web comprises using rotating tools.

4. The process of claim 3 wherein the rotating tools comprise dado blades.

5. The process of claim 3 wherein the rotating tools travel in opposite directions.

6. The process of claim 3 wherein the rotating tools travel in the same direction.

7. A process of making a sandwich-like product, said process comprising, in any desired order:
moving an extruded web of material having spaced upper and lower walls and a plurality of spacers extending between the upper and lower walls, the spacers being spaced from each other to define a plurality of flutes;
stopping the web and removing portions of the extruded web while the extruded web is stopped using at least one movable tool to create a lightened web;
folding the lightened web such that the flutes of untreated regions of the lightened web become cells of a middle core;
resuming movement of the web;
applying outer skins to the tops and bottoms of the cells of the middle core to create a multi-layered web.

8. The process of claim 7 further comprising cutting the multi-layered web.

9. The process of claim 7 wherein removing portions of the extruded web while the extruded web is stopped comprising using multiple movable tools.

10. The process of claim 7 wherein removing portions of the extruded web comprises using at least one rotating tool.

11. The process of claim 10 wherein removing portions of the extruded web comprises using multiple dado blades.

12. The process of claim 11 wherein the dado blades travel in opposite directions.

13. The process of claim 11 wherein the dado blades travel in the same direction.

14. The process of claim 7 wherein the extruded web is heated prior to removing portions of the extruded web.

15. A process of making a sandwich-like product, said process comprising, in any desired order:
removing rectangular-shaped portions from an extruded web to create alternating treated and untreated rectangular areas in a lightened web, the extruded web having spaced upper and lower walls and a plurality of spacers extending between the upper and lower walls, the spacers being spaced from each other to define a plurality of flutes;
folding the lightened web such that untreated regions of the extruded web become blocks, each of the blocks comprising a plurality of cells arranged in a row;
joining adjacent blocks to each other to create a create a middle core;
applying outer skins to the middle core.

16. The process of claim 15 wherein removing portions of the extruded web comprises removing portions of the extruded web while leaving at least one of the upper and lower walls of the extruded web remaining.

17. The process of claim 15 wherein removing portions of the extruded web comprises using rotating tools.

18. The process of claim 15 wherein the rotating tools comprise dado blades.

19. The process of claim 18 wherein the dado blades travel in opposite directions.

20. The process of claim 18 wherein the dado blades travel in the same direction.

Assignees

• Bradford Co

Inventors

• Bradford Judson A

Classifications

• B29D99/0089

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

• B32B27/06

  as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)} · CPC title

• B30B15/062

  Press plates · CPC title

• B29C48/0022

  combined with cutting · CPC title

• B29C48/0021

  combined with joining, lining or laminating · CPC title