CA1253312A - One piece seamless enclosure and methods of making it - Google Patents
One piece seamless enclosure and methods of making itInfo
- Publication number
- CA1253312A CA1253312A CA000493458A CA493458A CA1253312A CA 1253312 A CA1253312 A CA 1253312A CA 000493458 A CA000493458 A CA 000493458A CA 493458 A CA493458 A CA 493458A CA 1253312 A CA1253312 A CA 1253312A
- Authority
- CA
- Canada
- Prior art keywords
- panels
- enclosure
- set forth
- piece
- seamless enclosure
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
- B29D99/0021—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
- B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D22/00—Producing hollow articles
- B29D22/003—Containers for packaging, storing or transporting, e.g. bottles, jars, cans, barrels, tanks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/10—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
- B29C43/12—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies using bags surrounding the moulding material or using membranes contacting the moulding material
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Rigid Containers With Two Or More Constituent Elements (AREA)
- Laminated Bodies (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
Methods and apparatus for providing a one-piece seamless enclosure include a plurality of panels each having a foam core surrounded by a fiber reinforced cloth or woven material. The panels are joined inside of an outer mold. An inner inflatable mold is inserted into the area between the panels and pressurized. Resin is pumped into the cavity between the inner and outer molds and then cured. The molds are removed and a one piece seamless enclosure or shelter is provided.
Methods and apparatus for providing a one-piece seamless enclosure include a plurality of panels each having a foam core surrounded by a fiber reinforced cloth or woven material. The panels are joined inside of an outer mold. An inner inflatable mold is inserted into the area between the panels and pressurized. Resin is pumped into the cavity between the inner and outer molds and then cured. The molds are removed and a one piece seamless enclosure or shelter is provided.
Description
lZ~331'~
BACKCROUND OF THE INVENTION
Enclosures are generally designed to be fabricated using various components subsequently joined together;
corner joints and other seams have to be sealed to prevent environmental damage.
OBJECTS OF THE INVENTION
It ;s an object of this invention to provide a novel one-piece seamless enclosure and method of making same.
It is a further object of this invention to provide an improved enclosure which does not require corner joints or other seams which have to be sealed to protect it against the environment.
It is a further object of this invention to provide an improved one-piece seamloss construction hrlvinR hi~h thermnl insulntjoll.
BRIEP SUMMARY OF THE lNVENTlON
In accordance with the present invention, an enclosure or shelter of a plurality of sides is fabricated into a single seamless unit. Six or more individual panels, in a preferred embodiment, include foam cores .
~ . . _ . . . _ , . . , _ _ . , _ . . . _ . .
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completely surrounded by fiber reinforced cloth or woven material, such as fiberglass. The panels have mitered edges for subsequent nesting of the panels in the corners of the enclosure or shelter. In manufacturing, a rigid outer mold and an inflatable and collapsible inner mold are provided on opposite sides of the panels.
~fter the inner mold is pressurized, resin is pumped into the cavit~ between the molds to impregnate the fibrous material surrounding the panels. The resin is then cured and the molds are dism~ntled to permit removal of the enclosure.
Other objects and advantages of the present invention will be apparent and suggest themselves to those skilled in the art from a reading of the following specification and claims taken in conjunction with the accompanying drawings.
~RIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is an isonletric view illustrating a mDlding system for molding a ono-piece scamlcss cnclosllrc, in accordance with the prcsent Invenei.on;
Fig. 2 is an cxploded view illustrating some of the main elements illustrated in Fig. l;
Fig. 2~ is an isometric view of a finished enclosure, in accordance with the present invention;
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Fig. 3 is a cross-sectional view illustrating the corner connections for the inner mold illustrated in Fig. 2;
Fig. 4 is an exploded view illustrating some of the elements of Fig. 3; and Figs. 5, 6 and 7 illustrate the steps in joining two of the six panels used to form the enclosure, in accordance with the present invention.
DESCRIPTION OF THE IN ENTION
The making of an integral one-piece enclosure of the present invention requires inner and outer molds disposed on opyosite sides of foam core panels having fibrous outer skins with the edges of the foam panels in physical contact with each other. Resin under pressure is then injected into the cavity between the inner and outer molds. The resin impregnates the skins of the panels. After curing the resin a one-piece enclosure is formed and the inner and outer molds are rcmovctl.
Rcferring to IZig. l, tlll outcr mold 10 colllprises Z0 a rigid alllnlinuln ~h~.Ll 12, a strong reinforccment frame 14, top member 6 and bottom membcr 8. The top and bottom members may take different forms and may be held firmly in place by external forces or tied together by cables tnot illustrated). Six foam panels, formed by high density foam frame 16 and low density foam matcrial18, are located at their edges inside of the aluminum shell 12.
The foam panels each include an outer skin 2~.
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An outer skin, such as skin 20, surrounds each of the six located foam panels and is made of a fibrous material adapted to have resin impregnated therein. An inner mold 26, to be described in connection with Figs. 2 and 3 is assembled inside of the panels which make up the shelter to be formed.
After the inner mold is in place, a source of pressure 28, which may be any suitable gas, is applied to the inner mold 26. When resin is injected into the system from a source 22 by means of a pump 24, the skin material of all the panels becomes impregnated with the resin. After the resin has been properly cured, a rigid composite external surface is provided around all of the panels which make up the enclosure.
Because all of the details relating to the foam and re-sin operation are not directly related to the present invention, they are not illustrated in detail. U.S. Patents 4,568,057 and 4,608,453 which issued, respectively, on February 4, 1986 and August 26, 1986 to The Budd Company relate also to features des-cribed herein.
Figure 2 is an exploded view illustrating some of the main elements involved in the present invention, with 12S33~'~
.. .. .
some emphasis on the details of one embodiment of an inflatable inner mold which may be used in practicing the present invention. ~ig. 2A illustrates a completed enclosure 59 having an opening 61and illustrates the final product resulting from the means and methods used in the present invention.
The inner mold 26 includes six somewhat similar frame assemblies for six sides of an enclosure each comprising four angle members with some of the angle members being included in more than one frame assembly.
All parts making up the assemblies must be assembled individually inside ofthe six panels such as the foam panels 30, which are pre-located inside of the outer rigid shell 12 which acts as a wall for the outer mold.
An opening 61is provided in one of the panels to permit entry and exit. Means for sealing the openings in the enclosure are not described or illustrated.
After the assemblies for the inner mold 26 are in place within the shell 12, six nylon sheets, such as a sheet 36 are secured to the six frame assemblies.
Means for senling the joining nroas and corners oE the assemblies ~rc provi~lcd, ns will be described. The completed sealed frame assemblies with their nylon sheets provide the inner mold of the present invention.
~ n Fig. 2, a typical one of six frame assemblies 34, comprises four nngle members 36, 38, 40 and 42. The angle members 36, 38, 40, and 42 are adapted to receive 12533~;~
the nylon sheet 32 thereon. Corner elements 44, 46, 48 and 50 are provided to join the angle members 36, 38, 40 and 42 with other joining angle members. Only the frame assembly 34 is described, it being understood that the explanation also applies to other unnumbered frame assemblies and angle elements.
Referring to Fig. 3, there is illustrated a means for joining the various parts to form the inner mold. Only one joint between adjacent frames is illustrated, it being understood that all the frames are joined in a substantially similar manner. After the parts for the frames have been brought into the panels to form the shelter, means are provided to join the frames, formed by the angle members of Fig. 2, and also to join the lS adjacent nylon film sheets so as to have an inner mold capable of receiving pressure ~"ith the joined areas preventing leakage when gas under pressure is pumped into the assembly comprising the inner mold. The inner mold is described in one of thc aforementioned copcnding applications entitled "An Innor Influeablo nnd Col1apsible Mold".
An angle member 11 comprising surfaces 13 and lS is considered to be typical of all of the angle members illustrated in Fig. 2. After the angle members have been installed (with the foam panels already in place), means for sealing and receiving the nylon sheets are provided.
_.. _ . _ . .. ,. , _. _, .. ... .. _ _ . , . .. _ . ... .. . , . _ . , .. . .. . . . , . . . _ .
~2S~3~;~
A strip of nylon 17 having sealants 19 and 21 on opposite sides theTeof is inserted on the surfaces 13 and 15 of the angle member 11. The strip 17 with the sealants is pre-made. The nylon strip 17, with its sealants 19 and 21, is applied around all of the angle members, with foursuch members providing a single frame.
The strip 17 provides bridging strength at the corners.
Nylon sheets 23 and 25 are then secured to the layer of sealant 21. After the nylon sheets 23 and 25 are in place, a second pre-made nylon strip 27 having a sealant 29 is secured to the nylon sheets all around the angle members making up the frame assemblies. The multiple sealants and nylon strips assure that the nylon sheets are adequately joined together and not subject lS to leakage. The nylon strip 27 provides additional bridging strength at the corners. With this arrangement, the possible leakage paths through the sealants at the corners are lengthened.
All of the areas between the corners of the angle membcrs making up the framo assemblies are joincd togethcr ln the samc manner ns Ill~lstrrlted in ~ig~ 3. In the ease of the corners when threc frames and film sheets meet, additional means are used to join togethcr tlle thrce units.
Referring to I:ig. 4, three angle members 31, 33 and 35 having a space therebetween areadapted to receive a corner bracket. Tape sections 39, 41 and ~3 having sealants on both sides are adapted to sit into the corner i2S~31;~
bracket 37. The various tape sections 39, 41, and 43 with their sealants are continuations oE a tape such as nylon strip 17 with sealants 19 and 21 applied on either side.
s The corners of the nylon film sheets 45, 47 and 49 are adapted to fit into the tapes 39, 41 and 43 which include the sealant thereon. Following the installation ofthe nylon strips, a group of tapes Slt 53 and S5 are inserted. The tape sections Sl, 5_ and 55 have adhesive applied thereto. The tapes Sl, 53 and SS may be continuations of strips such as strip 27 illustrated in Fig. 3 having a sealant Z9.
It is thus seen that the present invention provides adequate sealing where the edges of the nylon sheets join as well as sealing the corners where three areas of the nylon films and frames meet. The multiple layers of sealant and use of nylon strips assures a strong seal to prevent leakage or rupture of the inflatable assembly making up thc inncr mold whcrl hi6h prcssurc is appliecl.
RC r~rrillg to I~l~s. S, 6 allcl 7, two oc the six foam panels 52 and 54 making ~Ip the enclosure are illustrated.
These foam panels 52 and 54 inclutde the low and high density foam material therein with only one density being illustrated. The foam panels 52 and 54 are mitered at portions 56 and 58 so that they may be joined at the corners 3~L~f~
in the manner illustrated in Fig. 5.
Fig. S illustrates the two panels 52 and 54 before they are joined together. To insure structural integrity at the outer joint, fiberglass flaps are used on both the inside and outside surfaces of the panels. The outside flaps include fiberglass pieces 60 and 6Z.
The inside flaps include fiberglass pieces 64and 66 on the panelsS2 and 54. In order to position the outside flaps 60 and 62, since fiberglass has a lD minimal inherent rigidity before resin impregnation, the use of a "helper sheet" 68 positions the flaps against the shell 12, which comprises part of the outer mold while adjacent panels are slid into position. Once the adjacent panels, such as panels 52 and 54, are located, the helper sheet 68 is removed. As illustrated in Fig. S, the inner ~-fiberglass flaps 64 and 66 are folded out oE the way until the corner joint is completed when they are unfolded as illustrated in Fig. 7.
The panel 52 includes an outer fiberglass skin 70 and an inner fibcrglass skin 72. Likcwise, tho ~anel S~, as woll a9 nll tho other ~nll0l9 not i.l lustrtltcd, includc tlll outer fibcr~lass skin 7~ nnd tln inncr fiberglass skin 76. Thc skins around thc panels may comprise a singlc piece in some cases.
Fig 6 illustrates another step in the assembly of the panels in which an aluminum "Y" shaped extrustion 78 ~ g ," ~ .. 1,, ,, ~, . ., .. ____ . _ .. __ _ ___ ,~,_ ._ ,_ .. _~ . .... . .
lZ5331;~
is inserted into the corner between the panels. The "Y" member, which may be metal,serves to tie together the inner skins of adjacent panels to provide structural integrity of the inside corners due to internal or S externral pressure loading. The "Y" member provides a shear tie between the foam cores of the panels and their inner and outer skins at the corners. This essentially provides full rigidity of the panels around the corners.
Fig. 7 illustrates the fiberglass flaps 64 and 66 extended from their folded positions over the extrusion 78. It is seen that the joining areas of adjacent panels have additional reinforcement by using the inner and outer fiberglass flaps.
.. __ . . ~.. . _ .. . _ . . .. . . . ... .. . .....
BACKCROUND OF THE INVENTION
Enclosures are generally designed to be fabricated using various components subsequently joined together;
corner joints and other seams have to be sealed to prevent environmental damage.
OBJECTS OF THE INVENTION
It ;s an object of this invention to provide a novel one-piece seamless enclosure and method of making same.
It is a further object of this invention to provide an improved enclosure which does not require corner joints or other seams which have to be sealed to protect it against the environment.
It is a further object of this invention to provide an improved one-piece seamloss construction hrlvinR hi~h thermnl insulntjoll.
BRIEP SUMMARY OF THE lNVENTlON
In accordance with the present invention, an enclosure or shelter of a plurality of sides is fabricated into a single seamless unit. Six or more individual panels, in a preferred embodiment, include foam cores .
~ . . _ . . . _ , . . , _ _ . , _ . . . _ . .
~2S331~
completely surrounded by fiber reinforced cloth or woven material, such as fiberglass. The panels have mitered edges for subsequent nesting of the panels in the corners of the enclosure or shelter. In manufacturing, a rigid outer mold and an inflatable and collapsible inner mold are provided on opposite sides of the panels.
~fter the inner mold is pressurized, resin is pumped into the cavit~ between the molds to impregnate the fibrous material surrounding the panels. The resin is then cured and the molds are dism~ntled to permit removal of the enclosure.
Other objects and advantages of the present invention will be apparent and suggest themselves to those skilled in the art from a reading of the following specification and claims taken in conjunction with the accompanying drawings.
~RIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is an isonletric view illustrating a mDlding system for molding a ono-piece scamlcss cnclosllrc, in accordance with the prcsent Invenei.on;
Fig. 2 is an cxploded view illustrating some of the main elements illustrated in Fig. l;
Fig. 2~ is an isometric view of a finished enclosure, in accordance with the present invention;
12S331~
Fig. 3 is a cross-sectional view illustrating the corner connections for the inner mold illustrated in Fig. 2;
Fig. 4 is an exploded view illustrating some of the elements of Fig. 3; and Figs. 5, 6 and 7 illustrate the steps in joining two of the six panels used to form the enclosure, in accordance with the present invention.
DESCRIPTION OF THE IN ENTION
The making of an integral one-piece enclosure of the present invention requires inner and outer molds disposed on opyosite sides of foam core panels having fibrous outer skins with the edges of the foam panels in physical contact with each other. Resin under pressure is then injected into the cavity between the inner and outer molds. The resin impregnates the skins of the panels. After curing the resin a one-piece enclosure is formed and the inner and outer molds are rcmovctl.
Rcferring to IZig. l, tlll outcr mold 10 colllprises Z0 a rigid alllnlinuln ~h~.Ll 12, a strong reinforccment frame 14, top member 6 and bottom membcr 8. The top and bottom members may take different forms and may be held firmly in place by external forces or tied together by cables tnot illustrated). Six foam panels, formed by high density foam frame 16 and low density foam matcrial18, are located at their edges inside of the aluminum shell 12.
The foam panels each include an outer skin 2~.
~ZS~31;~
An outer skin, such as skin 20, surrounds each of the six located foam panels and is made of a fibrous material adapted to have resin impregnated therein. An inner mold 26, to be described in connection with Figs. 2 and 3 is assembled inside of the panels which make up the shelter to be formed.
After the inner mold is in place, a source of pressure 28, which may be any suitable gas, is applied to the inner mold 26. When resin is injected into the system from a source 22 by means of a pump 24, the skin material of all the panels becomes impregnated with the resin. After the resin has been properly cured, a rigid composite external surface is provided around all of the panels which make up the enclosure.
Because all of the details relating to the foam and re-sin operation are not directly related to the present invention, they are not illustrated in detail. U.S. Patents 4,568,057 and 4,608,453 which issued, respectively, on February 4, 1986 and August 26, 1986 to The Budd Company relate also to features des-cribed herein.
Figure 2 is an exploded view illustrating some of the main elements involved in the present invention, with 12S33~'~
.. .. .
some emphasis on the details of one embodiment of an inflatable inner mold which may be used in practicing the present invention. ~ig. 2A illustrates a completed enclosure 59 having an opening 61and illustrates the final product resulting from the means and methods used in the present invention.
The inner mold 26 includes six somewhat similar frame assemblies for six sides of an enclosure each comprising four angle members with some of the angle members being included in more than one frame assembly.
All parts making up the assemblies must be assembled individually inside ofthe six panels such as the foam panels 30, which are pre-located inside of the outer rigid shell 12 which acts as a wall for the outer mold.
An opening 61is provided in one of the panels to permit entry and exit. Means for sealing the openings in the enclosure are not described or illustrated.
After the assemblies for the inner mold 26 are in place within the shell 12, six nylon sheets, such as a sheet 36 are secured to the six frame assemblies.
Means for senling the joining nroas and corners oE the assemblies ~rc provi~lcd, ns will be described. The completed sealed frame assemblies with their nylon sheets provide the inner mold of the present invention.
~ n Fig. 2, a typical one of six frame assemblies 34, comprises four nngle members 36, 38, 40 and 42. The angle members 36, 38, 40, and 42 are adapted to receive 12533~;~
the nylon sheet 32 thereon. Corner elements 44, 46, 48 and 50 are provided to join the angle members 36, 38, 40 and 42 with other joining angle members. Only the frame assembly 34 is described, it being understood that the explanation also applies to other unnumbered frame assemblies and angle elements.
Referring to Fig. 3, there is illustrated a means for joining the various parts to form the inner mold. Only one joint between adjacent frames is illustrated, it being understood that all the frames are joined in a substantially similar manner. After the parts for the frames have been brought into the panels to form the shelter, means are provided to join the frames, formed by the angle members of Fig. 2, and also to join the lS adjacent nylon film sheets so as to have an inner mold capable of receiving pressure ~"ith the joined areas preventing leakage when gas under pressure is pumped into the assembly comprising the inner mold. The inner mold is described in one of thc aforementioned copcnding applications entitled "An Innor Influeablo nnd Col1apsible Mold".
An angle member 11 comprising surfaces 13 and lS is considered to be typical of all of the angle members illustrated in Fig. 2. After the angle members have been installed (with the foam panels already in place), means for sealing and receiving the nylon sheets are provided.
_.. _ . _ . .. ,. , _. _, .. ... .. _ _ . , . .. _ . ... .. . , . _ . , .. . .. . . . , . . . _ .
~2S~3~;~
A strip of nylon 17 having sealants 19 and 21 on opposite sides theTeof is inserted on the surfaces 13 and 15 of the angle member 11. The strip 17 with the sealants is pre-made. The nylon strip 17, with its sealants 19 and 21, is applied around all of the angle members, with foursuch members providing a single frame.
The strip 17 provides bridging strength at the corners.
Nylon sheets 23 and 25 are then secured to the layer of sealant 21. After the nylon sheets 23 and 25 are in place, a second pre-made nylon strip 27 having a sealant 29 is secured to the nylon sheets all around the angle members making up the frame assemblies. The multiple sealants and nylon strips assure that the nylon sheets are adequately joined together and not subject lS to leakage. The nylon strip 27 provides additional bridging strength at the corners. With this arrangement, the possible leakage paths through the sealants at the corners are lengthened.
All of the areas between the corners of the angle membcrs making up the framo assemblies are joincd togethcr ln the samc manner ns Ill~lstrrlted in ~ig~ 3. In the ease of the corners when threc frames and film sheets meet, additional means are used to join togethcr tlle thrce units.
Referring to I:ig. 4, three angle members 31, 33 and 35 having a space therebetween areadapted to receive a corner bracket. Tape sections 39, 41 and ~3 having sealants on both sides are adapted to sit into the corner i2S~31;~
bracket 37. The various tape sections 39, 41, and 43 with their sealants are continuations oE a tape such as nylon strip 17 with sealants 19 and 21 applied on either side.
s The corners of the nylon film sheets 45, 47 and 49 are adapted to fit into the tapes 39, 41 and 43 which include the sealant thereon. Following the installation ofthe nylon strips, a group of tapes Slt 53 and S5 are inserted. The tape sections Sl, 5_ and 55 have adhesive applied thereto. The tapes Sl, 53 and SS may be continuations of strips such as strip 27 illustrated in Fig. 3 having a sealant Z9.
It is thus seen that the present invention provides adequate sealing where the edges of the nylon sheets join as well as sealing the corners where three areas of the nylon films and frames meet. The multiple layers of sealant and use of nylon strips assures a strong seal to prevent leakage or rupture of the inflatable assembly making up thc inncr mold whcrl hi6h prcssurc is appliecl.
RC r~rrillg to I~l~s. S, 6 allcl 7, two oc the six foam panels 52 and 54 making ~Ip the enclosure are illustrated.
These foam panels 52 and 54 inclutde the low and high density foam material therein with only one density being illustrated. The foam panels 52 and 54 are mitered at portions 56 and 58 so that they may be joined at the corners 3~L~f~
in the manner illustrated in Fig. 5.
Fig. S illustrates the two panels 52 and 54 before they are joined together. To insure structural integrity at the outer joint, fiberglass flaps are used on both the inside and outside surfaces of the panels. The outside flaps include fiberglass pieces 60 and 6Z.
The inside flaps include fiberglass pieces 64and 66 on the panelsS2 and 54. In order to position the outside flaps 60 and 62, since fiberglass has a lD minimal inherent rigidity before resin impregnation, the use of a "helper sheet" 68 positions the flaps against the shell 12, which comprises part of the outer mold while adjacent panels are slid into position. Once the adjacent panels, such as panels 52 and 54, are located, the helper sheet 68 is removed. As illustrated in Fig. S, the inner ~-fiberglass flaps 64 and 66 are folded out oE the way until the corner joint is completed when they are unfolded as illustrated in Fig. 7.
The panel 52 includes an outer fiberglass skin 70 and an inner fibcrglass skin 72. Likcwise, tho ~anel S~, as woll a9 nll tho other ~nll0l9 not i.l lustrtltcd, includc tlll outer fibcr~lass skin 7~ nnd tln inncr fiberglass skin 76. Thc skins around thc panels may comprise a singlc piece in some cases.
Fig 6 illustrates another step in the assembly of the panels in which an aluminum "Y" shaped extrustion 78 ~ g ," ~ .. 1,, ,, ~, . ., .. ____ . _ .. __ _ ___ ,~,_ ._ ,_ .. _~ . .... . .
lZ5331;~
is inserted into the corner between the panels. The "Y" member, which may be metal,serves to tie together the inner skins of adjacent panels to provide structural integrity of the inside corners due to internal or S externral pressure loading. The "Y" member provides a shear tie between the foam cores of the panels and their inner and outer skins at the corners. This essentially provides full rigidity of the panels around the corners.
Fig. 7 illustrates the fiberglass flaps 64 and 66 extended from their folded positions over the extrusion 78. It is seen that the joining areas of adjacent panels have additional reinforcement by using the inner and outer fiberglass flaps.
.. __ . . ~.. . _ .. . _ . . .. . . . ... .. . .....
Claims (8)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A one-piece seamless enclosure comprising:
(a) a plurality of panels each including a foam core surrounded by fiber reinforced material;
(b) each of said panels being joined together at its edge to an adjacent panel to provide a hollow enclosure between said panels, and (c) said fiber reinforced material being impregnated with cured resin to form said one-piece seamless enclosure.
(a) a plurality of panels each including a foam core surrounded by fiber reinforced material;
(b) each of said panels being joined together at its edge to an adjacent panel to provide a hollow enclosure between said panels, and (c) said fiber reinforced material being impregnated with cured resin to form said one-piece seamless enclosure.
2. A one-piece seamless enclosure as set forth in claim 1 wherein said plurality of panels comprise six panels with at least one of said panels having an opening therein.
3. A one-piece seamless enclosure as set forth in claim 2 wherein at least one of said panels include an opening therein.
4. A method of forming a hollow, one-piece, seamless enclosure comprising:
(a) providing a plurality of panels each having a foam core completely surrounded by fiber reinforced material and having mitered edges for nesting of said panels;
(b) providing an outer mold around said panels;
(c) loading said panels into said outer mold with said panels being located at their mitered edges to provide an enclosure;
(d) inserting and pressurizing an inner inflatable mold in said enclosure to engage the inner walls of said panel and to form a cavity between said inner and outer molds; and (e) pumping resin into the cavity between said inner and outer molds to impregnate the fiber reinforced material surrounding said panels.
(a) providing a plurality of panels each having a foam core completely surrounded by fiber reinforced material and having mitered edges for nesting of said panels;
(b) providing an outer mold around said panels;
(c) loading said panels into said outer mold with said panels being located at their mitered edges to provide an enclosure;
(d) inserting and pressurizing an inner inflatable mold in said enclosure to engage the inner walls of said panel and to form a cavity between said inner and outer molds; and (e) pumping resin into the cavity between said inner and outer molds to impregnate the fiber reinforced material surrounding said panels.
5. A method as set forth in claim 4 wherein "Y" members are inserted between the mitered edges of said panels.
6. A method as set forth in claim 4 wherein additional steps of curing said resin and removing said inner and outer molds are provided.
7. A method as set forth in claim 6 wherein reinforcement means are provided around said outer mold.
8. A method as set forth in claim 4 wherein six panels are provided.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US66362684A | 1984-10-22 | 1984-10-22 | |
| US663,626 | 1984-10-22 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1253312A true CA1253312A (en) | 1989-05-02 |
Family
ID=24662637
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000493458A Expired CA1253312A (en) | 1984-10-22 | 1985-10-21 | One piece seamless enclosure and methods of making it |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JPS61104944A (en) |
| CA (1) | CA1253312A (en) |
| DE (1) | DE3537402A1 (en) |
Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH0747316Y2 (en) * | 1989-04-11 | 1995-11-01 | 水野産業株式会社 | Assembled container material plate |
| FR2675424A1 (en) * | 1991-04-16 | 1992-10-23 | Haras Ind | METHOD FOR MANUFACTURING LUMINOUS COUPOLES FOR THE PRODUCTION OF COSTS EQUIPPED WITH A PROFILE REBORD |
| US5785788A (en) * | 1992-02-20 | 1998-07-28 | Fischer Advanced Composite Components Gmbh | Process for manufacturing a stowage container for use in an aircraft |
| AT397906B (en) * | 1992-02-20 | 1994-08-25 | Fischer Adv Components Gmbh | PLASTIC CONTAINER |
| DE19739291C1 (en) | 1997-09-08 | 1998-08-06 | Deutsch Zentr Luft & Raumfahrt | Cut=outs for windows in fibre reinforced sandwich structure |
| FR2953382B1 (en) * | 2009-12-03 | 2014-04-25 | Christophe Stanek | COMPACT MOBILE REFRIGERATION AND COOKING MODULE |
-
1985
- 1985-10-17 JP JP23228585A patent/JPS61104944A/en active Pending
- 1985-10-21 DE DE19853537402 patent/DE3537402A1/en not_active Withdrawn
- 1985-10-21 CA CA000493458A patent/CA1253312A/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| JPS61104944A (en) | 1986-05-23 |
| DE3537402A1 (en) | 1986-04-24 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |