# US 2008/0184663 A1 · Structural composite panel, method of fabrication, and construction

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- Number: US 2008/0184663 A1
- Document ID: US20080184663A1
- Status: Published application
- Kind: A1
- Application number: 12/028,000
- Filed: 2008-02-07
- Published: 2008-08-07
- Earliest claimed: 2007-02-07
- Inventors: Armen Martirossyan; Petros Keshishian
- Web page: https://patentgrep.com/patent/US20080184663A1

## CPC

- E04C 2/044: {of concrete (E04C2/049 takes precedence)}
- B29C 44/1276: {the preformed parts being three dimensional structures which are wholly or partially penetrated by the foam}
- B29C 44/326: {Joining the preformed parts, e.g. to make flat or profiled sandwich laminates}
- E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S)
- 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 (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)

## Abstract

A machine for fabricating a composite structural panel is provided that receives trusses vertically and feeds them into a foam spray chamber driven by first and second drive mechanisms. The drive mechanisms form the filler material and maintain the trusses in place while a cutting blade trims off excess foam.

## Claims

### Claim 1

A machine for fabricating a composite structural panel having a plurality of trusses held together by foam, the machine comprising:
an elongated generally flat conveyer system having a plurality of elongated cylindrical rollers positioned horizontally along the conveyer system for receiving trusses vertically positioned along the conveyer system in spaced-apart relation and allowing the trusses to traverse thereacross;
first and second drive mechanisms each having at least one generally flat portion on a side thereof, the first drive mechanism having the at least one generally flat portion positioned coplanar to the conveyer system for engaging and feeding one side of the panel therethrough, the second drive mechanism being positioned in opposed relation to the first drive mechanism for engaging and feeding another side of the panel therethrough, the first and second drive mechanisms collectively defining a foam spray chamber therebetween;
a plurality of spray nozzles positioned across the conveyer system in spaced-apart relation and pointed toward the foam spray chamber for forming foam between each side of the panel; and
first and second cutting blades being positioned adjacent a side portion of the first and second drive mechanisms respectively for trimming excess foam from the panel.

### Claim 2 (depends on 1)

The machine as in claim 1 further comprising liquid expandable foam configured to be expelled from the spray nozzles into the chamber.

### Claim 3 (depends on 1)

The machine as in claim 1 wherein the first and second drive mechanisms are triangular shaped.

### Claim 4 (depends on 1)

The machine as in claim 1 wherein each of the first and second drive mechanisms further includes a plurality of rollers and a secondary belt extending over the rollers.

### Claim 5

A method of fabricating a composite structural panel, the method comprising the steps of:
a) selecting a composite structural panel for fabrication having at least two structural shells, an expandable insulating material therebetween, and a plurality of truss members embedded therebetween; and
b) forming a structural panel fabrication machine for fabricating the composite structural panel selected in step (a), the machine having:
an elongated generally flat conveyer system having a plurality of elongated cylindrical rollers positioned horizontally along the conveyer system for receiving trusses vertically positioned along the conveyer system in spaced-apart relation and allowing the trusses to traverse thereacross,
first and second drive mechanisms each having at least one generally flat portion on a side thereof, the first drive mechanism having the at least one generally flat portion positioned coplanar to the conveyer system for engaging and feeding one side of the panel therethrough, the second drive mechanism being positioned in opposed relation to the first drive mechanism for engaging and feeding another side of the panel therethrough, the first and second drive mechanisms collectively defining a foam spray chamber therebetween,
a plurality of spray nozzles positioned across the conveyer system in spaced-apart relation and pointed toward the foam spray chamber for forming foam between each side of the panel, and
first and second cutting blades being positioned adjacent a side portion of the first and second drive mechanisms respectively for trimming excess foam from the panel.