Method of manufacturing a composite panel
OwnerLuther I. Dickens, William C. Nannyinventors
Life of this patent
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Abstract
A method of forming a panel structure useful in building construction and the like includes the steps of heating a heat expandable plastic in a separable mold having a cavity with the configuration of the resultant panel to form a panel core and adhering thin reinforcing strips to the front and back surfaces of the core. Control over the dimensions and configuration of the panel is obtained by adhering the strips to the core in the mold while applying heat thereto whereby core shrinkage is minimized. The strips may be adhered to the core during initial heating of the plastic material to form the core or may be adhered to the core in the mold subsequent to core formation.
Claims9
A method of manufacturing a composite panel comprising the steps of
- heating a heat expandable plastic material in particular form in a separable closed mold to expand the material into a panel core having the shape of the mold cavity, and
- adhering thin reinforcing strips in spaced apart relation to the front and back surfaces of the expanded core while the core is heated with the ends of predetermined strips extending from edges of the core.
A method of forming a composite panel comprising
- forming a separable non-ferrous mold with magnets buried in the mold parts along predetermined lines,
- placing thin ferrous reinforcing strips with a heat-activated adhesive on inner surfaces thereof on the mold pieces along predetermined lines to mount the strips thereat,
- closing the mold with said strips mounted thereon and filling the mold with a heat expandable plastic material in particulate form,
- heating the material in the mold to expand the material into a molded panel core having the size and shape of the mold interior, and at the same time, adhering said strips to said core, and
- removing said panel core and attached strips as a composite panel.
A method of manufacturing a panel comprising
- (a) filling a closed mold with a heat expandable plastic material in divided form.
- (b) heating the material in said mold to expand the material into a cellular core for a panel,
- (c) removing the core from the mold whereby said core shrinks,
- (d) placing a first plurality of thin, flat, reinforcing strips on the back surface of the core at least along the edges thereof with a heat activated adhesive on the surfaces of the strips contacting the core,
- (e) placing a second plurality of thin, flat, reinforcing strips on the front surface of the core at least along the cores edges with a heat activated adhesive on the surfaces of the strips contacting the core,
- (f) replacing the core in the mold with said plurality of strips thereon,
- (g) closing mold and heating the interior thereof to re-expand the core to the mold dimensions and to bond the strips to the expanded core, and
- (h) removing the core and bonded strips from the mold as a panel having the dimensions of the mold and which does not shrink upon cooling.
Dependencies are inferred from the claim text.