Composite steel structural plastic sandwich plate systems

A method of making a structural laminate comprising the steps of:

• positioning a first metal layer and a second metal layer in a spaced apart relationship such that a core cavity is formed between facing surfaces of the first and second metal layer, each of the first and second metal layers having a thickness in a range from 0.2 mm to 30 mm;
• providing an aperture through the thickness of one of the first and second metal layers,
• providing an uncured plastic material to said core cavity, wherein the uncured plastic is provided to the core cavity through the aperture and wherein the aperture is sealed with a metal plug;
• and
• curing the uncured plastic material such that the plastic material adheres to the facing surfaces of the first and second metal layers and such that the plastic material has a modulus of elasticity greater than 200 MPa.

A method of making a structural laminate comprising the steps of:

• positioning a first metal layer and a second metal layer in a spaced apart relationship such that a core cavity is formed between facing surfaces of the first and second metal layer, each of the first and second metal layers having a thickness in a range from 0.2 mm to 30 mm;
• providing a void form to said core cavity;
• providing an uncured plastic material to said core cavity;
• and
• curing the uncured plastic material such that the plastic material adheres to the facing surfaces of the first and second metal layers and such that the plastic material has a modulus of elasticity greater than 200 MPa.

A method of making a structural laminate member comprising:

• positioning a surface of a first metal plate opposite and spaced apart from a surface of a second metal plate to form a core cavity, each of the first and second metal plates having a thickness in a range from 0.2 mm to 30 mm, one of the first and second metal plates having a portion adapted to be welded, the portion adapted to be welded defining a weld margin in a part of the core cavity adjacent to the portion adapted to be welded, wherein the portion adapted to be welded is a peripheral edge;
• providing an uncured plastic material to the core cavity such that the weld margin is devoid of plastic;
• and
• curing the uncured plastic material such that the plastic material adheres to the first and second metal layers and such that the plastic material has a modulus of elasticity greater than 200 Mpa.

A method of making a structural laminate member comprising:

• positioning a surface of a first metal plate opposite and spaced apart from a surface of a second metal plate to form a core cavity, each of the first and second metal plates having a thickness in a range from 0.2 mm to 30 mm, one of the first and second metal plates having a portion adapted to be welded, the portion adapted to be welded defining a weld margin in a part of the core cavity adjacent to the portion adapted to be welded;
• providing a void form to said core cavity;
• providing an uncured plastic material to the core cavity such that the weld margin is devoid of plastic;
• and
• curing the uncured plastic material such that the plastic material adheres to the first and second metal layers and such that the plastic material has a modulus of elasticity greater than 200 Mpa.

A method of making a double walled structure comprising:

• forming a first wall by positioning a first metal layer spaced apart from a second metal layer such that a core cavity is formed between facing surfaces of the first and second metal layers;
• forming a second wall by positioning a third metal layer spaced apart from a fourth metal layer such that a core cavity is formed between facing surfaces of the third and fourth metal layers;
• supporting the first wall in a position adjacent to and spaced apart from the second wall such that an access cavity is defined between the second metal layer of the first wall and the third metal layer of the second wall;
• providing an uncured first plastic material to the core cavity of the first wall through an aperture in at least one of the first and the second metal layer of the first wall, the aperture permitting communication between the access cavity of the double walled structure and the core cavity of the first wall;
• providing an uncured second plastic material to the core cavity of the second wall through an aperture in at least one of the third and the fourth metal layer of the second wall, the aperture permitting communication between the access cavity of the double walled structure and the core cavity of the second wall;
• curing the uncured first plastic material such that the first plastic material adheres to the facing surfaces of the first and second metal layers of the first wall and such that the plastic material has a modulus of elasticity greater than 200 MPa;
• and
• curing the uncured second plastic material such that the second plastic material adheres to the facing surfaces of the third and fourth metal layers of the second.