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US 7,201,112 B2Granted
Filled shell devices and methods of manufacturing
OwnerMark W. Jolleyinventor
Life of this patent
Estimating the term…
Abstract
A method of manufacturing an apparatus, such as a board, is provided where a shell is formed in a forming mold cavity and the shell is substantially filled with a core in a filling mold cavity that substantially prevents distortion of the shell during filling.
Claims17
A method of manufacturing a board, the method comprising:
- providing upper and lower sheets of material;
- inserting the upper and lower sheets of material into an interior of a first mold cavity;
- clamping perimeters of the upper and lower sheets of material;
- forming the upper and lower sheets of material to the interior of the first mold cavity following clamping of the perimeters of the upper and lower sheets of material to form a shell having a single hollow interior;
- filling the entire shell with an expandable material;
- and
- preventing the shell from substantially deforming during filling with the expandable material by inserting the shell into a second mold cavity having a shape substantially conforming to the shell, the second mold cavity being different from the first mold cavity.
4 more elements
A method of manufacturing a board, the method comprising:
- providing upper and lower sheets of material;
- inserting the upper and lower sheets of material into an interior of a first mold cavity, including positioning the upper sheet of material above the lower sheet of material, providing a gasket between the perimeter of the upper sheet and the perimeter of the lower sheet, and clamping a perimeter of the upper sheet of material and a perimeter of the lower sheet of material;
- forming the upper and lower sheets of material to the interior of the first mold cavity to form a shell having a single hollow interior;
- filling the entire shell with an expandable material;
- and
- preventing the shell from substantially deforming during filling with the expandable material by inserting the shell into a second mold cavity having a shape substantially conforming to the shell, the second mold cavity being different from the first mold cavity.
3 more elements
A method of manufacturing a board, the method comprising:
- providing upper and lower sheets of material;
- inserting the upper and lower sheets of material into an interior of a first mold cavity, including positioning the upper sheet of material above the lower sheet of material and clamping a perimeter of the upper sheet of material and a perimeter of the lower sheet of material;
- spacing at least a portion of the upper and lower sheets of material apart by blowing fluid between the upper and lower sheets of material and passing a fluid inlet tube through a gasket;
- forming the upper and lower sheets of material to the interior of the first mold cavity to form a shell having a single hollow interior;
- filling the entire shell with an expandable material;
- and
- preventing the shell from substantially deforming during filling with the expandable material by inserting the shell into a second mold cavity having a shape substantially conforming to the shell, the second mold cavity being different from the first mold cavity.
4 more elements
Dependencies are inferred from the claim text.