# US 2013/0280472 A1 · Method of making a sandwich-type composite panel having a living hinge and panel obtained by performing the method > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2013/0280472 A1 - Document ID: US20130280472A1 - Status: Published application - Kind: A1 - Application number: 13/453,269 - Filed: 2012-04-23 - Published: 2013-10-24 - Earliest claimed: 2012-04-23 - Assignees: Global IP Holdings, LLC - Inventors: Darius J. Preisler; Christopher A. Heikkila - Web page: https://patentgrep.com/patent/US20130280472A1 ## CPC - B32B 27/065: {of foam} - B29C 51/145: {having at least one layer of textile or fibrous material combined with at least one plastics layer} - B29C 59/007: {Forming single grooves or ribs, e.g. tear lines, weak spots (by moulding B29C37/0057; folding lines B29C53/06; in metal articles B21D17/00; by cutting B26D3/08)} - B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure - B32B 3/28: characterised by a layer comprising a deformed thin sheet {, i.e. the layer having its entire thickness deformed out of the plane}, e.g. corrugated, crumpled (B32B29/08 takes precedence) - B32B 5/022: {Non-woven fabric} - B32B 5/245: {another layer next to it being a foam layer} - B32B 27/08: of synthetic resin - B32B 27/12: next to a fibrous or filamentary layer - E04B 2/58: with elongated members of metal - B29K 2023/12: {PP, i.e. polypropylene} - B29K 2105/04: cellular or porous - B29K 2105/256: {Sheets, plates, blanks or films} - B29L 2031/22: Hinges {, pivots} - B32B 5/18: characterised by features of a layer {of} foamed material - B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA - B32B 2266/0292: Thermoplastic elastomer - B32B 2274/00: Thermoplastic elastomer material - B32B 2471/02: Carpets - B32B 2605/003: Interior finishings - Y10T 156/10: Methods of surface bonding and/or assembly therefor - Y10T 428/23979: Particular backing structure or composition - Y10T 428/24504: Component comprises a polymer [e.g., rubber, etc.] - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - 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) - E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001}) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method of making a sandwich-type composite panel having a living hinge from a stack of material is provided. The stack includes first and second reinforced thermoplastic skins heated to a softening temperature and a thermoplastic cellular core disposed between the skins. The first skin is stretchable when heated to the softening temperature. A pressure is applied to the stack after the step of heating to form the composite panel. A portion of the composite panel is crushed at a predetermined location simultaneously with the step of applying to locally compact and separate the cellular core at the predetermined location to form two side portions of the panel and a crushed portion of the panel between the two side portions. The first skin stretches during the step of crushing while remaining intact between the two side portions. The skins bond together at the predetermined location to form the living hinge. ## Claims ### Claim 1 A method of making a sandwich-type composite panel having a living hinge, the method comprising: providing a stack including first and second reinforced thermoplastic skins and a thermoplastic cellular core disposed between the skins; heating the skins to a softening temperature wherein the first skin is stretchable when heated to the softening temperature; applying a pressure to the stack after the step of heating to form the composite panel; and crushing a portion of the composite panel at a predetermined location simultaneously with the step of applying to locally compact and separate the cellular core at the predetermined location to form two side portions of the panel and a crushed portion of the panel between the two side portions, the first skin stretching during the step of crushing while remaining intact between the two side portions, the first and second skins at the predetermined location bonding together to form the living hinge between the two side portions. ### Claim 2 (depends on 1) The method as claimed in claim 1, wherein the first and second skins are chemically bonded to each other at the predetermined location to form the living hinge. ### Claim 3 (depends on 1) The method as claimed in claim 1, wherein the stack includes a thermoplastic covering layer for covering the second skin. ### Claim 4 (depends on 3) The method as claimed in claim 3, wherein the covering layer is a resin carpet. ### Claim 5 (depends on 4) The method as claimed in claim 4, wherein the resin is polypropylene. ### Claim 6 (depends on 1) The method as claimed in claim 1, wherein the cellular core is a honeycomb core. ### Claim 7 (depends on 1) The method as claimed in claim 1, wherein each of the skins is fiber reinforced. ### Claim 8 (depends on 1) The method as claimed in claim 1, wherein the thermoplastic of the skins and the core is polypropylene. ### Claim 9 (depends on 1) The method as claimed in claim 1, wherein the panel has a thickness in the range of 5 to 25 mm. ### Claim 10 (depends on 1) The method as claimed in claim 1, wherein at least one of the skins is a woven skin. ### Claim 11 (depends on 1) The method as claimed in claim 1, wherein at least one of the skins is a woven polypropylene skin. ### Claim 12 (depends on 1) The method as claimed in claim 1, wherein the pressure lies in a range including 10×105 Pa to 30×105 Pa. ### Claim 13 (depends on 9) The method as claimed in claim 9, wherein the living hinge has a thickness less than 3 mm. ### Claim 14 (depends on 13) The method as claimed in claim 13, wherein the living hinge has a thickness of 2 mm or less. ### Claim 15 A method of making a carpeted sandwich-type composite panel having a living hinge, the method comprising: providing a stack including first and second reinforced thermoplastic skins, a thermoplastic cellular core disposed between the skins and a thermoplastic covering layer for covering the second skin; heating the skins to a softening temperature wherein the first skin is stretchable when heated to the softening temperature; applying a pressure to the stack after the step of heating to form the carpeted composite panel; and crushing a portion of the composite panel at a predetermined location simultaneously with the step of applying to locally compact and separate the cellular core at the predetermined location to form two side portions of the panel and a crushed portion of the panel between the two side portions, the first skin stretching during the step of crushing while remaining intact between the two side portions, the covering layer and first and second skins at the predetermined location bonding together to form the living hinge between the two side portions. ### Claim 16 (depends on 15) The method as claimed in claim 15, wherein the covering layer and first and second skins are chemically bonded to each other at the predetermined location to form the living hinge. ### Claim 17 (depends on 15) The method as claimed in claim 15, wherein the thermoplastic of the skins, the covering layer and the core is polypropylene. ### Claim 18 (depends on 15) The method as claimed in claim 15, wherein the living hinge has a thickness less than 3 mm. ### Claim 19 (depends on 1) A panel of sandwich-type composite structure made by performing the method according to claim 1, the panel comprising: a stack including: a first skin of a reinforced thermoplastics material; a cellular core of a thermoplastics material; and a second skin of a reinforced thermoplastics material; and a living hinge defined by the crushed portion. ### Claim 20 (depends on 15) A carpeted panel of sandwich-type composite structure made by performing the method according to claim 15, the panel comprising: a stack including: a first skin of a reinforced thermoplastics material; a cellular core of a thermoplastics material; a second skin of a reinforced thermoplastics material; and a covering layer of a thermoplastics material; and a living hinge defined by the crushed portion.