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US3697633A
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US
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Structural core
Assignee: HOWARD M EDGAR
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Filing: 1970-07-21
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Granted: 1972-10-10
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Expires: 1990-07-21
Abstract
Abstract A structural core is formed by filling a rigid frame with an expanded synthetic polymer composition which may include fillers and which is adhesively secured to the frame. The resultant foam filled frame is then sliced to form panel cores. Finished panels are made by laminating panel faces to one or both sides of the core, or by painting, or otherwise treating the panel core. In one embodiment, the frame may be built up of a plurality of frame members with removable spacers to permit sawing of the foamed material without sawing the frame. The cores and panels thus constructed are useful in doors, walls, floors, roofs, etc. in buildings and in furniture and other structures outside the building industry. Reinforcing, electrical conductors, plumbing, etc. may also be built into the cores.
Inventors
- 👤 Howard M Edgar
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 23:10
CPC Classifications
B; B29; B29C; B29C44/00; B29C44/34; B29C44/58; B29C44/02; B29C44/12; B29C44/1271; B29C44/56; B29C44/5627; B29C44/5654; B29L; B29L2031/00; B29L2031/10; Y; Y10; Y10S; Y10S264/00; Y10S264/32; Y10T; Y10T156/00; Y10T156/10; Y10T156/1052; Y10T156/1059; Y10T156/1062; Y10T156/1075; Y10T428/00; Y10T428/24; Y10T428/24479; Y10T428/24488; Y10T428/249921; Y10T428/249953; Y10T428/249982; Y10T428/249984
Claims Analysis
Total Claims: 11
Claim 1
Independent Claim
35 words
The process of claim 1 further including the preliminary step of assembling the frame from a plurality of frame members, each of which frame members defines the exterior configuration of the desired resultant structural core.
Claim 2
Dependent Claim
46 words
The process of claim 2 further including the placement of spacers between the frame members so that the frame members are spaced from each other during the filling step and including the removal of the spacers after the filling step and prior to the slicing step.
Claim 3
Dependent Claim
30 words
The process of claim 1 wherein said frame is composed of unitary panels, each of which defines a side of said frame and said panels are cut during said slicing.
Claim 4
Dependent Claim
200 words
A process for manufacturing structural cores comprising the steps of: providing a rigid frame having an external configuration corresponding to the external configuration of the desired structural cores, a height equal to at least a plurality of thicknesses of the desired structural cores and a substantially open interior; filling the open interior of the frame with a lightweight expanded polymer composition by injecting an expandable polymer composition into said frame which when set will be adhesive bonded to the interior surface of the frame and allowing the polymer composition to expand and set to a rigid condition; and slicing the expanded polymer filled frame into a plurality of structural cores by cutting the expanded polymer filled frame into a plurality of panel-like units having a rigid border which is that part of the frame cut from the frame surrounding the expanded, set polymer composition in the interior; said polymer composition being adhesively bonded to the interior of said rigid borders and said rigid frame being so constructed that the surface area of the frame in contact with the resin in a structural core is small compared with the surface area of the foam when the filled frame is so cut.
Claim 5
Dependent Claim
34 words
The process as defined in claim 5 wherein the expanded polymer composition contains at least one material selected from the group consisting of dye, pigment, filler, fire retardent material, reinforcing fibers and nucleating particles.
Claim 6
Dependent Claim
37 words
The process as defined in claim 5 wherein the frame includes means defining at least one opening which is not filled with expanded polymer for forming passageways through the structural cores sliced from an expanded polymer composition.
Claim 7
Dependent Claim
57 words
The process as defined in claim 7 further comprising the step of positioning electrical conductors in said frame, said conductors being so constructed and arranged as to be substantially surrounded by the expanded polymer composition and to form at least a pair of individual electrical conductors in the structural cores sliced from the expanded polymer filled frame.
Claim 8
Dependent Claim
51 words
The process as defined in claim 7 further comprising the step of positioning a plurality of plumbing elements in said frame such that when the expanded polymer filled frame is sliced the structural cores formed thereby include at least one plumbing element adapted for use in connection with a plumbing fixture.
Claim 9
Dependent Claim
57 words
The process as defined in claim 5 further comprising the step of positioning electrical conductors in said frame, said conductors being so constructed and arranged as to be substantially surrounded by the expanded polymer composition and to form at least a pair of individual electrical conductors in the structural cores sliced from the expanded polymer filled frame.
Claim 10
Dependent Claim
51 words
The process as defined in claim 5 further comprising the step of positioning a plurality of plumbing elements in said frame such that when the expanded polymer filled frame is sliced the structural cores formed thereby include at least one plumbing element adapted for use in connection with a plumbing fixture.
Claim 11
Dependent Claim
55 words
The process as defined in claim 5 further comprising the step of positioning at least one reinforcing member in said frame, said member being so constructed and arranged as to be substantially surrounded by said expanded polymer composition and to form a reinforcing member in the structural cores sliced from the expanded polymer filled frame.
References Cited (Backward Citations)
No citation records indexed.
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1975-10-10 | 1976-04-10 | 1976-10-10 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1979-10-10 | 1980-04-10 | 1980-10-10 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1983-10-10 | 1984-04-10 | 1984-10-10 | $7700.00 | Window Closed / Lapsed |