WO2002009934B1 - Panel structure with rigid foam core - Google Patents

Panel structure with rigid foam core

Info

Publication number
WO2002009934B1
WO2002009934B1 PCT/US2001/023839 US0123839W WO0209934B1 WO 2002009934 B1 WO2002009934 B1 WO 2002009934B1 US 0123839 W US0123839 W US 0123839W WO 0209934 B1 WO0209934 B1 WO 0209934B1
Authority
WO
WIPO (PCT)
Prior art keywords
panel
panels
core
peripheral
fiber layers
Prior art date
Application number
PCT/US2001/023839
Other languages
French (fr)
Other versions
WO2002009934A8 (en
WO2002009934A1 (en
Inventor
Satish J Doshi
Leslie E Smith
John C Montagna
Zbigniew Roman Pedzinski
Original Assignee
Durakon Ind Inc
Satish J Doshi
Leslie E Smith
John C Montagna
Zbigniew Roman Pedzinski
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Durakon Ind Inc, Satish J Doshi, Leslie E Smith, John C Montagna, Zbigniew Roman Pedzinski filed Critical Durakon Ind Inc
Priority to JP2002516087A priority Critical patent/JP2004504961A/en
Priority to CA002407092A priority patent/CA2407092A1/en
Priority to BR0112801-9A priority patent/BR0112801A/en
Priority to MXPA03000697A priority patent/MXPA03000697A/en
Priority to DE10196244T priority patent/DE10196244T1/en
Priority to AU2001278069A priority patent/AU2001278069A1/en
Priority to GB0225924A priority patent/GB2377669B/en
Publication of WO2002009934A1 publication Critical patent/WO2002009934A1/en
Publication of WO2002009934A8 publication Critical patent/WO2002009934A8/en
Publication of WO2002009934B1 publication Critical patent/WO2002009934B1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • 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
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B32B2323/04—Polyethylene
    • B32B2323/043—HDPE, i.e. high density polyethylene

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Laminated Bodies (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)

Abstract

A panel structure (10) includes a rigid foam center core (30) sandwiched between two outer skin fiber layers (20,24). The core is preferably polyurethane, polypropylene, polystyrene and mixtures, as well as polyphenylne oxide and blends. The fiber layers (20,24) may be bi-directional fabric, a unidirectional material or a random weave mat which is impregnated with an epoxy or resin binder. The fibers themselves may fiberglass, polypropylene, Kevlar or carbon. The rigid foam core is thermoplastic polyolefin (TPO), high density polyethylene (HDPE) or acrylonitrile butadieme styrene which are molded into the skin layers (20,24) with peripheral lips (22,26). The lips (22,26) are compressed together and form a peripheral bead or seal (28).

Claims

AMENDED CLAIMS [received by the International Bureau on 14 January 2002 (14.01.02); original claims 1, 8 and 15 amended; remaining claims unchanged (3 pages)]
1. A panel structure comprising, in combination, a first panel having a p]anar portion and a peripheral 3ip, a second panel, having a planar portion and a peripheral lip, said panels scaled about said peripheral lips and defining an interior space, one of said planar portions defining a surface finished to receive paint, a r.igid core disposed in and substantially filling said interior space, .iaid rigid core including a center layer having opposed £ lanar faces and first and second fibex layers secured to said opposed planar faces.
2. The pant 1 structure of laim 1 wherein material of said panels is selected from the group consisting of high density polyethylene, thermoplastic polyolefin and acrylonitrile butadiene styrene.
3. The pa el structure of Claim 1 wherein said structure is a tc nneau cover.
4. The par el structure of Claim 1 wherein material of said center l yM- of said rigid core is selected from the group consistinςi of aluminum honeycomb, polyυrethane foam, polypropylene f im and polystyrene foam.
5. The panel structure of Claim 1 wherein said fiber layers are wover , unidirectional or random fibers.
6. The ccmposite structure of Claim 1 wherein said fiber layers include an epoxy or resin binder.
"7. The p;mel structure of Claim 3 further including adhesive layer., disposed between said rigid core and said panels .
8. panel structure comprising, in combination, a first outer panel having a first, planar portion and a first peripheral 1 p, a second oute.:' panel having a second, planar portion and a second peripheial lip, said panels sealed about said peripheral lips an 3 defining an interior space, said first an 1 said second planar portions defining at least one surface having a smooth finish adapted to receive paint, a core disposed in and substantially filling said interior space, : aid core including a center layer having substantially parallel, planar faces and first and second fiber layers secured to a respective one of said parallel planar faces.
9. The pan :1 structure of Claim 8 wherein said panel material is selected from the group consisting of high density polye hylene, thermoplastic polyolefin and acryloni trile butadiene styrene.
10. The par-≥.l structure of Claim 8 defining a tonne.au cover .
11. The panel structure of Claim 8 wherein material of said center laynr of said core is selected from the group consisting of aluminum honeycomb, polyurethane foam, polypropylene roam, polystyrene foam and a blend of polystyrene and polyphenylene oxide foam.
12. The pa el structure of Claim 8 wherein said fibers layers are wover , unidirectional or random fibers.
13. The composite structure of Claim 8 wherein said fiber layers include an epoxy or resin binder.
14. The p:.nel structure of Claim 8 further including adhesive layers disposed between said core and said panels.
15. A method of forming a panel structure comprising the steps of, providing upp-:r and lower vacuum molds, at least one of said molds adapted to produce an appearance surface; providing a "irst heated panel of a moldable plastic material to such lower mold and vacuum forming said first, panel; providing a preformed rigid core having a an intermediate regi n and first and second outer fiber layers; ap lyin1 a adhesive to such outer fiber layers; disposing said rigid core within such formed first panel; providing a second heated panel of a moldable plastic material to said upper mold and vacuum forming said second panel; and disposing said upper mold adjacent said lower mold and sealing said panels together to defin a peripheral seal.
16. The method of Claim 15 further including the step of trimming excels material adjacent such peripheral seal,
1.7. The method of Claim 15 wherein said adhesive is applied to said outer surface layers by spraying.
18. The e iihod of Claim 15 wherein said panels are utilized after extrusion and before cooling.
19. The i thod of Claim 15 wherein said panels are thermoplastic o^lefin.
20. The method of Claim 15 wherein said panels are high density polyeth len .
PCT/US2001/023839 2000-07-28 2001-07-27 Panel structure with rigid foam core WO2002009934A1 (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
JP2002516087A JP2004504961A (en) 2000-07-28 2001-07-27 Panel structure with rigid foam core
CA002407092A CA2407092A1 (en) 2000-07-28 2001-07-27 Panel structure with rigid foam core
BR0112801-9A BR0112801A (en) 2000-07-28 2001-07-27 Rigid Foam Core Panel Structure
MXPA03000697A MXPA03000697A (en) 2000-07-28 2001-07-27 Panel structure with rigid foam core.
DE10196244T DE10196244T1 (en) 2000-07-28 2001-07-27 Panel structure with rigid foam core
AU2001278069A AU2001278069A1 (en) 2000-07-28 2001-07-27 Panel structure with rigid foam core
GB0225924A GB2377669B (en) 2000-07-28 2001-07-27 Panel structure with rigid foam core

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US62782400A 2000-07-28 2000-07-28
US09/627,824 2000-07-28

Publications (3)

Publication Number Publication Date
WO2002009934A1 WO2002009934A1 (en) 2002-02-07
WO2002009934A8 WO2002009934A8 (en) 2002-03-07
WO2002009934B1 true WO2002009934B1 (en) 2002-07-04

Family

ID=24516289

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2001/023839 WO2002009934A1 (en) 2000-07-28 2001-07-27 Panel structure with rigid foam core

Country Status (8)

Country Link
JP (1) JP2004504961A (en)
AU (1) AU2001278069A1 (en)
BR (1) BR0112801A (en)
CA (1) CA2407092A1 (en)
DE (1) DE10196244T1 (en)
GB (1) GB2377669B (en)
MX (1) MXPA03000697A (en)
WO (1) WO2002009934A1 (en)

Families Citing this family (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SE0500904L (en) * 2005-04-22 2006-10-23 Arca Systems Ab A thermoplastic product structure for increased resistance to cold flow
US20070101679A1 (en) * 2005-10-25 2007-05-10 L&L Products, Inc. Panel structure
GB2453512B (en) * 2007-10-08 2009-11-25 Gurit Composite laminated article and manufacture thereof
GB2448468B (en) 2007-10-08 2009-09-30 Gurit Composite laminated article and manufacture thereof
US8484918B2 (en) * 2008-10-15 2013-07-16 Merkel Composite Technologies, Inc. Composite structural elements and method of making same
US8438816B2 (en) 2008-10-23 2013-05-14 John Murchie Composite panel
FR3008630B1 (en) * 2013-07-16 2015-12-18 Filippo Mariagiuseppina Di SURFACE TREATMENT OF EXPANDED PLASTIC MATERIALS
GB2550355A (en) * 2016-05-16 2017-11-22 Hexcel Reinforcements Uk Ltd Moulding materials
WO2019213314A1 (en) 2018-05-02 2019-11-07 Abc Technologies Inc. Tonneau cover
US11465477B2 (en) 2018-05-02 2022-10-11 Abc Technologies Inc. Tonneau cover
CN111231821B (en) * 2020-03-06 2020-12-29 淮阴师范学院 Protective device for transportation and storage of automobile headlamps

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4463043A (en) * 1981-08-26 1984-07-31 Sprinkmann Sons Corporation Building panel
US4801483A (en) * 1987-02-13 1989-01-31 Power-Tel Products Group, Inc. High strength, light weight structural composite and method of preparing same
US5283028A (en) * 1990-05-02 1994-02-01 Penda Corporation Process for producing a selectively reinforced thermoformed article
US5275860A (en) * 1992-05-28 1994-01-04 Foam Design Consumer Products, Inc. Foam product for recreational products
US5624726A (en) * 1995-01-09 1997-04-29 Minnesota Mining And Manufacturing Company Insulation blanket
US5743586A (en) * 1997-02-06 1998-04-28 Covercraft Industries Hard shell tonneau cover

Also Published As

Publication number Publication date
MXPA03000697A (en) 2003-10-15
GB2377669B (en) 2004-03-10
CA2407092A1 (en) 2002-02-07
WO2002009934A8 (en) 2002-03-07
WO2002009934A1 (en) 2002-02-07
GB0225924D0 (en) 2002-12-11
AU2001278069A1 (en) 2002-02-13
GB2377669A (en) 2003-01-22
BR0112801A (en) 2003-09-09
DE10196244T1 (en) 2003-06-18
JP2004504961A (en) 2004-02-19

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