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US 5,589,243 AGranted
Reinforced foam cores and method and apparatus of production
AssigneeWebcore Technologies, Inc.
InventorStephen W. Day
Life of this patent
Estimating the term…
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AssigneeWebcore Technologies, Inc.
InventorStephen W. Day
Estimating the term…
Rigid foam boards and alternating absorptive fibrous web sheets are adhered to form core panels or billets. Porosity is maintained in the webs for forming integral structural ties by absorbing resin applied to overlying sandwich panel skins. Beveled foam recesses adjacent web edge portions form structural resin fillets, and protruding edge portions form expanded connections to the skins. Core panels oriented with their webs crossing are layered with web sheets to form enhanced panels. Boards or core panels and web sheets arranged in inclined stacks form second core panels having webs intersecting panel edges or faces at acute angles. Boards of alternating different physical properties and web sheets are bonded to form reinforced panels having differing interior and exterior densities. Compressible foam panels are used in place of or with web sheets to make bendable core panels. Foam between web edge portions is recessed for bonding a settable material to the edge portions.
A reinforced foam core panel adapted for use between generally parallel skins, comprising a plurality of boards of rigid plastics foam material with each board having opposite faces, a strip of porous and fibrous flexible web material overlying at least one of said faces of each said board, said boards of foam material arranged in a stack with said strips of web material disposed between said boards, means for connecting said boards of rigid foam material and said strips of porous and flexible fibrous web material together while maintaining substantial porosity throughout said strips of web material to form a core panel with said boards having opposite side surfaces and with said strips of web material having edge portions extending to said opposite side surfaces, said side surfaces of said boards being exposed for receiving an adhesive resin for attaching the skins to said side surfaces and to said edge portions of said strips of web material, the porosity of said strips of web material providing for the flow of resin through said strips to form integral tie webs connecting the skins, said boards of foam material defining fillet recesses within said side surfaces adjacent said edge portions of said strips of web material, and said recesses are adapted to receive the resin for increasing the bond of said strips to said skins.
A reinforced core panel having opposite side surfaces adapted to be attached to corresponding skins, comprising a plurality of pieces of rigid plastics foam material arranged to form a panel and with adjacent pieces having opposing faces, a plurality of strips of porous and fibrous flexible web material extending between and separating said opposing faces of said adjacent pieces, means for holding the adjacent said pieces and said strips together while maintaining substantial porosity throughout said strips to form a core panel with said pieces and edge portions of said strips of web material forming said opposite side surfaces of said core panel, said pieces and said edge portions of said strips of web material being exposed for receiving a curable adhesive resin for attaching the skins to said pieces and to said edge portions of said strips of web material, the porosity of said strips of web material providing for the flow of resin through said strips to form integral tie webs connecting the skins, said pieces defining fillet recesses adjacent said edge portions of said strips of web material, and said recesses are adapted to receive the resin for increasing the bond strength of said strips to the skins.
A reinforced foam core panel assembly having opposite sides formed by corresponding rigid skins, comprising a plurality of pieces of rigid plastics foam material arranged to form a panel, each said piece having opposite side surfaces adjacent said skins and with adjacent pieces having opposing faces, a plurality of thin webs of porous and fibrous flexible material disposed between and separating said opposing faces of said adjacent pieces, each of said webs having opposite edge portions terminating adjacent said skins and said opposite side surfaces of said pieces, means attaching the adjacent said pieces and said webs together while maintaining substantial porosity throughout said webs to form a core panel with said pieces and said edge portions of said webs forming opposite sides of said core panel, a curable adhesive resin attaching said skins to said pieces of foam material and to said edge portions of said webs, and said resin extends throughout said porous webs and impregnates said webs to bond the fibers of said edge portions to said skins and to form separate integral tie webs connecting said skins.
Dependencies are inferred from the claim text.