Method and apparatus for forming objects having a core and an outer surface structure
AssigneeGreat Dane LLC
InventorsRichard B. Mullininx, P. Alan Whiten
Life of this patent
Estimating the term…
Abstract
A method of making at least partially foam-filled sandwich panels includes providing a panel shell, moving at least one of a portion of a first and/or second panel facer or a side member away from the panel volume, thereby defining an opening between the volume and an exterior area. A dispenser proximate the opening moves across at least a portion of the opening while dispensing an amount of a foam agent into the volume through the opening. A press has three platens, a third platen of which is secured to at least one of a portion of the first and/or second facer and the at least one side member and is moveable with respect to the first platen and the second platen in response to a control system.
Claims21
A method of making a sandwich structure enclosing an amount of a core material generated by an expanded agent material, comprising:
- providing a shell that encloses a volume;
- providing a press having a plurality of platens and having a frame and a control system;
- providing a dispenser movable on the frame responsively to the control system at a predetermined speed and operable to dispense an amount of the agent material at a predetermined rate;
- disposing the shell within the press so that the platens secure the shell in a position;
- providing an opening in the shell sufficient so that a pour of the agent material into the volume through the opening at the predetermined rate made by the dispenser while moving at the predetermined speed deposits an amount of agent material into the volume that is sufficient to generate the entire said amount of core material;
- and
- moving the dispenser proximate the opening while causing the dispenser to dispense the sufficient amount of agent material into the volume through the opening.
A method of making a sandwich structure enclosing an amount of a core material generated by an expanded agent material, comprising:
- providing a shell comprising a first facer, a second facer spaced apart from the first facer, and at least one side member extending between the first facer and the second facer about a circumferential periphery of the shell so that the first facer, the second facer, and the at least one side member enclose a volume;
- providing an opening
- in at least one of the first facer, the second facer, and the at least one side member, or
- between the at least one side member and at least one of the first facer and the second facer,
- at or generally parallel to a seam between the at least one side member and one of the first facer and the second facer and extending a distance of at least about 2% of the entire length of the circumferential periphery;
- and
- providing a movable dispenser proximate the opening and moving the dispenser across at least a portion of the opening, while causing the dispenser to dispense an amount of the agent material into the volume through the opening that is sufficient to generate the entire said amount of core material.
A method of making a sandwich panel enclosing an amount of foam, comprising:
- providing a panel shell comprising
- a first generally planar facer,
- a second generally planar facer generally parallel to and spaced apart from the first facer, and
- at least one side member extending between the first facer and the second facer so that the first facer, the second facer, and the at least one side member enclose a volume;
- moving at least one of
- a portion of at least one of the first facer and the second facer with respect to a respective remainder of the at least one of the first facer and the second facer, and
- the at least one side member away from the volume, thereby defining an opening between the volume and an area exterior to the panel shell;
- providing a movable dispenser proximate the opening and moving a dispenser across at least a portion of the opening, while causing the dispenser to dispense an amount of a foam agent into the volume through the opening that is sufficient to generate the entire said amount of foam in the volume;
- and
- after causing the dispenser to dispense the sufficient amount, moving the at least one of the portion and the at least one side member to a position in communication with at least one other of the first facer, the second facer, and the at least one side member to thereby close the opening and enclose the volume.
A method of making a sandwich panel enclosing an amount of foam, comprising:
- providing a panel shell comprising
- a first generally planar facer,
- a second generally planar facer generally parallel to and spaced apart from the first facer, and
- at least one side member extending between the first facer and the second facer so that the first facer, the second facer, and the at least one side member enclose a volume, and wherein the panel shell forms a generally rectangular prism;
- inserting the panel shell between opposing platens of a press, so that the first facer abuts a first platen and the second facer abuts a second platen, wherein the press comprises a third platen that is pivotable with respect to the first platen;
- securing a portion of the first facer to the third platen;
- pivoting the third platen with respect to the first platen, thereby moving the portion of the first facer to a first position away from a portion of the at least one side member and defining an opening between the volume and an area exterior to the panel shell, wherein the opening has a first end and a second end opposite the first end;
- providing a movable foam dispenser proximate the opening and moving the foam dispenser between the first end and the second end, while causing the foam dispenser to dispense an amount of a foam agent into the volume through the opening that is sufficient to generate the entire said amount of foam;
- and
- after causing the foam dispenser to dispense the sufficient amount, moving the portion of the first facer to a second position in communication with the at least one side member to thereby close the opening and enclose the volume.
Dependencies are inferred from the claim text.