US4593449A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Manufacture of foam-filled panels and cores therefor
Assignee: MPM Industries Inc
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Filing: 1984-06-04
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Granted: 1986-06-10
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Expires: 2004-06-04
Abstract
Abstract Disclosed is a manner of making a core by shearing and bending a strip (36) of sheet metal into ribbons. The ribbons thereby constitute a series of troughs (53) and crests (52). The core is sandwiched between two skins (64,65). The crest and troughs are presented as tubes (66) extending into the interior of the core from an edge of the panel. Polyurethane foam is injected into these tubes. The foam rises and sticks the cores to the skins. The resulting panel is strong, rigid, durable, inexpensive, and extremely versatile.
Inventors
- 👤 Andrew G. Meray-Hovarth
- 👤 Ricky W. Myers
- 👤 Robert A. A. Palmberg
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 14:05
CPC Classifications
B; B29; B29C; B29C44/00; B29C44/02; B29C44/12; B29C44/1276; B32; B32B; B32B5/00; B32B5/18; B32B5/20; B29C44/34; B29C44/36; B29C44/38; B29C44/385; B29D; B29D24/00; B29D24/002; B29D24/005; B29D99/00; B29D99/0089; B32B3/00; B32B3/10; B32B3/12; B32B3/26; E; E04; E04C; E04C2/00; E04C2/30; E04C2/34; E04C2/3405; B29L; B29L2009/00; B29L2031/00; B29L2031/10; B32B2419/00; B32B2607/00; E04C2002/3444; E04C2002/3455; E04C2002/3472; E04C2002/3494; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/4998; Y10T428/00; Y10T428/24; Y10T428/24149; Y10T428/24157
Claims Analysis
Total Claims: 12
Claim 1
Independent Claim
170 words
Method of making a foamed, cored panel, the method comprising the steps: of forming a sandwich of two skins (64,65) and a core (62) placed between the skins; where the sandwich has these characteristics; that the core is so shaped and arranged with respect to the skins that when viewed from an edge of the panel the sandwich presents the appearance of a series of open-ended, straight-through tubes (66); that the walls of such a tube are not closed or continuous but are provided with many openings along the length of the tube; that the openings are of such a size, position, and nature, that the tube is substantially open to neighbouring tubes and to the skins; of injecting, into the tubes thus presented, the ingredients of plastic foam in liquid form; of causing the ingredients to foam and to substantially fill the tubes and all spaces between the skins, and to adhere to the core and to the skins; and of allowing the foam to cure and become hard.
Claim 2
Dependent Claim
170 words
Method of making a foamed, cored panel, the method comprising the steps: of forming a sandwich of two skins (64,65) and a core (62) placed between the skins; where the sandwich has these characteristics; that the core is so shaped and arranged with respect to the skins that when viewed from an edge of the panel the sandwich presents the appearance of a series of open-ended, straight-through tubes (66); that the walls of such a tube are not closed or continuous but are provided with many openings along the length of the tube; that the openings are of such a size, position, and nature, that the tube is substantially open to neighbouring tubes and to the skins; of injecting, into the tubes thus presented, the ingredients of plastic foam in liquid form; of causing the ingredients to foam and to substantially fill the tubes and all spaces between the skins, and to adhere to the core and to the skins; and of allowing the foam to cure and become hard.
Claim 3
Dependent Claim
26 words
Method of claim 1 where the sandwich is further characterized in that the skins are not attached to the core prior to injection of the foam.
Claim 4
Dependent Claim
21 words
Method of claim 1, including the step of clamping the sandwich in a press during injection and curing of the foam.
Claim 5
Dependent Claim
23 words
Method of claim 1, including the step of placing the skins in a substantially horizontal plane during injection and curing of the foam.
Claim 6
Dependent Claim
64 words
Method of claim 1, where the sandwich is further characterized in that the core has the further characteristics that when viewed from another edge (97) of the panel which is at right angles to the said edge, the sandwich presents an appearance of being substantially closed, such that a liquid injected from the said other edge would not, in substance, pass into the core.
Claim 7
Dependent Claim
48 words
Method of claim 1, including the step of injecting the liquid through a number of spaced nozzles (93) which are arranged around the perimeter of the sandwich, where the alignment of the nozzles is such that each directs a spray of liquid into and along the tubes (66).
Claim 8
Dependent Claim
47 words
Method of claim 6, including the step of arranging several sandwiches with their respective tubes (66) parallel with each other, and where the nozzles are set to direct the liquid into the tubes of all the sandwiches, so that several panels are made at the same time.
Claim 9
Dependent Claim
131 words
Method of claim 1, for making several panels at the same time, comprising the steps: of laying a bottom skin (64) on a flat horizontal support plate (72); of resting a core (62) on the bottom skin; of resting a top skin (65) on the core, to form a first sandwich (73); of building up a stack (74) of sandwiches one on top of another on the support plate; of providing a fence (76) around the perimeter of the sandwiches; of providing a clamp plate on top of the stack; of clamping the clamp plate and the support plate together onto the fence; of providing holes (92) in the fence at suitable intervals to receive injection nozzles (93); and of maintaining the clamp force during foaming and curing of the foam.
Claim 10
Dependent Claim
26 words
Method of claim 8, including the step of withdrawing the nozzles from the holes straight after injection to leave the holes free to act as vents.
Claim 11
Dependent Claim
39 words
Method of claim 8, including the step of placing the fence so that its height is slightly less than the total height of the stack, in order that the stack is slightly compressed when the plates are clamped together.
Claim 12
Dependent Claim
54 words
Method of claim 1, where the sandwich is further characterized in that the core is made of sheet material, which is so disposed that when the sandwich is viewed from the said edge, only the thickness of the sheet is visible, no part of the face of the sheet being visible in that view.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1989-06-09 | 1989-12-09 | 1990-06-10 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-06-09 | 1993-12-09 | 1994-06-10 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-06-09 | 1997-12-09 | 1998-06-10 | $7700.00 | Window Closed / Lapsed |