Panel derived thermoplastic composite components and products
AssigneeSmarter Planet LLC
InventorsMichael Robert O'Reilly, Gregory William Pronko, David Mayer de Rothschild, Frank P. Becking
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Abstract
Included herein are constructional techniques for forming thermoplastic composite panels into differently-shaped finished goods. The techniques described are especially useful in forming shaped goods having a complex core.
Claims20
A composite panel construction produced from a flat panel comprising a core and first and second thermoplastic cover layers bonded to the core, the composite panel construction made by a method of manufacture comprising:
- cutting core material from an interior surface of at least one of the cover layers while maintaining a bonded section between the core and the cover layers;
- heat setting a portion of the first cover layer in a shape following at least a portion of the cut surface of the core;
- and
- bonding a portion of the second cover layer to a portion of the first cover layer to at least partially close-off the construction.
A composite panel construction produced from a flat panel comprising a core and first and second thermoplastic cover layers bonded to the core, the composite panel construction made by a method of manufacture comprising:
- cutting core material from an interior surface of the cover layers while maintaining a bonded section between the core and the cover layers;
- inserting the body into a mold cavity and bonding the first cover layer around the core;
- and
- inserting the body into a same or a different mold cavity and bonding the second cover layer around the first cover layer.
Dependencies are inferred from the claim text.