# US 5,349,749 A · Process for forming a monolithic composite plate

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- Number: US 5,349,749 A
- Document ID: US5349749A
- Status: Granted
- Kind: A
- Application number: 07/936,766
- Filed: 1992-08-27
- Granted: 1994-09-27
- Earliest claimed: 1992-08-27
- Inventors: Leslie C. Fiedler
- Web page: https://patentgrep.com/patent/US5349749A

## CPC

- B29D 99/001: {Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings (articles with hollow walls B29D24/00)}
- B32B 3/18: characterised by an internal layer formed of separate pieces of material {which are juxtaposed side-by-side (B32B5/02 takes precedence)}
- B32B 3/26: 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 {(foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205); characterised by an apertured layer}
- 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 5/024: {Woven fabric}
- B32B 5/20: foamed in situ
- B32B 7/05: the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection (using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14)
- B32B 7/08: by mechanical means
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B65D 19/0095: {and each contact surface having a stringer-like shape}
- B32B 2262/101: Glass fibres
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/554: Wear resistance
- B65D 2519/00034: Plastic
- B65D 2519/00044: Combination, e.g. different elements made of different materials, laminates
- B65D 2519/00069: Plastic
- B65D 2519/00079: Combination, e.g. different elements made of different materials, laminates
- B65D 2519/00114: Combination, e.g. different elements made of different materials, laminates
- B65D 2519/00278: the load supporting surface and the base surface being identical
- B65D 2519/00293: made of more than one piece
- B65D 2519/00323: made of more than one piece
- B65D 2519/00333: contact surface having a stringer-like shape
- B65D 2519/00378: whereby at least one spacer is made of two or more pieces
- B65D 2519/00557: without separate auxiliary elements
- B65D 2519/00562: chemical connection, e.g. glued, welded, sealed
- Y10S 108/901: Synthetic plastic industrial platform, e.g. pallet
- Y10T 29/49616: Structural member making
- Y10T 29/4998: Combined manufacture including applying or shaping of fluent material
- Y10T 29/49993: Filling of opening
- Y10T 156/1025: to form undulated to corrugated sheet and securing to base with parts of shaped areas out of contact
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B65D: CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- Y10S: TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A method for forming a monolithic composite slat for a lightweight pallet. The slat is formed by adhering the crests of a corrugation to one side of a reinforcement sheet, placing another side of the reinforcement sheet in spaced, parallel relation with the corrugation and the first side such that the corrugation is situated between the first and second sides, inserting a flexible fiber in each trough of the corrugation and using each fiber to urge the trough toward the second side, inserting foam-forming material between the first and second sides, and allowing the material to cure, thereby forming a solid, foam-filled slat. The method is advantageous over that of the prior art, as it ensures that the corrugation remains in place during inserting of the foam-forming material.

## Claims

### Claim 1

A process for forming a solid, monolithic composite structural plate, said plate when formed comprising a reinforcement sheet having first and second parallel, spaced-apart sides, a corrugation between said sides having alternating crests and troughs, each of said crests defining a void thereunder, and buttresses filling said troughs and said voids, said buttresses being bonded to said corrugation and said sheet, said process comprising:
adhering a sequence of said crests of said corrugation to said first side, the material of said corrugation being initially flexible;
placing said second side of said sheet in spaced-apart, parallel relation with said corrugation and said first side such that said corrugation is situated between said first and second sides;
inserting a flexible strand in each trough, and moving said strands to engage the corrugation material and move said troughs toward said second side;
placing an initially fluid, foam-forming material in said troughs and said voids; and
curing said foam-forming material to form a solid foam buttress in each of said troughs and said voids, which bonds to said corrugation and to a respective side.

### Claim 2 (depends on 1)

A process according to claim 1, in which said foam-forming material is placed in only some of said troughs and said voids, some of said foam-forming material passing through said corrugation material to fill adjacent troughs and voids.

### Claim 3 (depends on 1)

A process according to claim 1, in which said strands move their respective troughs into contact with said second side.

### Claim 4 (depends on 3)

A process according to claim 3, in which said foam-forming material is placed in only some of said troughs and said voids, some of said foam-forming material passing through said corrugation material to fill adjacent troughs and voids.