Abstract An apparatus and method for producing composite materials and the materials made thereof are provided. In one form, one or more sheet metal materials are continuously extruded to shape and are combined with a core material in a rolling mill to provide a composite structure having improved characteristics imparted thereto by both core and encapsulating materials. The core material may comprise a plurality of reinforcing elements such as filaments, wires, whiskers or a grid fed to the bite of two extruded sheets or otherwise formed shapes which are made to flow over and around the reinforcing elements and to encapsulate same therebetween as the two sheets are roll bonded or welded together and reduced in thickness to form a third composite sheet formation thereof. In another form, individual articles are disposed on top of a first freshly extruded sheet and are encapsulated in a composite sheet formed of said first sheet and a second sheet disposed thereagainst and roll bonded thereto in a rolling mill. The oxide free, high-temperature condition of the two sheets, as extruded, is utilized to fabricate improved composite sheet materials without the difficulties normally experienced in fabricating sheet materials from cold stock.
Apparatus in accordance with claim 1 whereby said first and second materials are pressure weldable metal and said third material is a metal substantially stronger than said first and second materials and operative to reinforce the composite material, said fourth means comprising a rolling mill operative to deform said first and second sheets to cause same to flow over and around said third material as said materials are fed and to molecularly weld said first and second materials together.
Claim 2
Dependent Claim
15 words
Apparatus in accordance with claim 2 whereby said third material is composed of steel screening.
Claim 3
Dependent Claim
37 words
Apparatus in accordance with claim 1 whereby said third material is composed of a plurality of substantially flat reinforcing inserts and said third means is operative to selectively locate said inserts between said first and second materials.
Claim 4
Dependent Claim
38 words
Apparatus in accordance with claim 1 including automatic control means for predeterminately controlling operation of said third means to selectively dispense said third material between said first and second materials prior to passing same to said fourth means.
Claim 5
Dependent Claim
47 words
Apparatus in accordance with claim 1 including means for selectively dispensing said third material between said first and second materials, and printing means for selectively printing indicia on the surface of said composite material in registration with the selectively applied third material enCapsulated within said composite material.
Claim 6
Dependent Claim
76 words
Apparatus in accordance with claim 1 whereby one of said first and second materials is composed of a clear plastic material, means for operating said third means to predeterminately dispose said decorative material against the surface of one of said first and second sheet materials and a printing means operative to selectively print material onto the outer surface of said clear plastic material in registration with the third material disposed between said first and second sheets.
Claim 7
Dependent Claim
26 words
Apparatus in accordance with claim 7, said third means being operative to predeterminately dispense separate units of said third material between said first and second sheets.
Claim 8
Dependent Claim
42 words
Apparatus in accordance with claim 8 including a program control means for controlling the operation of said third means to predeterminately dispense said third material between said first and second sheets so as to predeterminately locate said units within said composite material.