Patent US5030488A successfully refreshed from Google Patents.
US5030488A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Laminates, panels and means for joining them
Assignee: CHEMICAL & POLYMER TECHNOLOGY Inc A CORP OF
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Filing: 1988-11-23
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Granted: 1991-07-09
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Expires: 2008-11-23
Abstract
Abstract Sandwich panels, i.e., laminates which comprise two metal sheets with a filled, reinforced resin core between and bonded to the metal sheets, are useful for structural and other uses. Combinations of metal sheets, resins, fillers, and reinforcement bonded together in the sandwich structure provided a laminate having a flexural modulus of at least 2.5 million psi, a rigidity index of at least about 2,000 and other unique properties which enable the laminates to be particularly useful for thin wall truck trailer body construction, as well as other uses. A rigidity index and a falling ball impact test for sandwich structures and panels are used to characterize the properties of these sandwich laminates. Methods of making the above sandwich laminates and means for joining the sandwich laminates and panels are disclosed, which provide for their particular usefulness in truck trailer body construction, as well as other structural and non-structural uses.
Inventors
- 👤 Igor Sobolev
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 17:36
CPC Classifications
B; B32; B32B; B32B15/00; B32B15/04; B32B15/08; B29; B29C; B29C70/00; B29C70/02; B29C70/028; B32B15/10; B32B15/20; B32B37/00; B32B37/14; B32B37/24; E; E04; E04C; E04C2/00; E04C2/02; E04C2/26; E04C2/284; E04C2/292; F; F16; F16B; F16B5/00; F16B5/01; B29K; B29K2705/00; B29K2705/02; B29K2711/00; B29K2711/14; B32B2307/00; B32B2307/50; B32B2307/54; B32B2307/542; B32B2307/546; B32B2307/558; B32B2311/00; B32B2311/24; B32B2439/00; F16B11/00; F16B11/006; F16B5/02; F16B5/04; Y; Y10; Y10T; Y10T428/00; Y10T428/13; Y10T428/1352; Y10T428/1355; Y10T428/1359; Y10T428/24; Y10T428/24008; Y10T428/24777; Y10T428/24793; Y10T428/24942; Y10T428/2495; Y10T428/24967; Y10T428/31504; Y10T428/31678; Y10T428/31703
Claims Analysis
Total Claims: 54
Claim 1
Independent Claim
72 words
A freight container body comprising at least one panel which is a structural laminate comprising two metal sheets and a thermoset reinforced resin core between and bonded to the two metal sheets, wherein each metal sheet has a thickness between 0.015 inch and about 0.1 inch, the thickness of the laminate is less than about 2 inches, and the panel is characterized by having a rigidity index of at least about 2,000.
Claim 2
Dependent Claim
72 words
A freight container body comprising at least one panel which is a structural laminate comprising two metal sheets and a thermoset reinforced resin core between and bonded to the two metal sheets, wherein each metal sheet has a thickness between 0.015 inch and about 0.1 inch, the thickness of the laminate is less than about 2 inches, and the panel is characterized by having a rigidity index of at least about 2,000.
Claim 3
Dependent Claim
23 words
A freight container body according to claim 1 wherein the laminate is characterized by having a rigidity index of at least about 3000.
Claim 4
Dependent Claim
14 words
A freight container body according to claim 1 wherein the metal sheets are aluminum.
Claim 5
Dependent Claim
14 words
A freight container body according to claim 1 wherein the resin core comprises microballoons.
Claim 6
Dependent Claim
104 words
A freight container body comprising at least one panel which is a structural laminate comprising two metal sheets and a thermoset reinforced resin core between and bonded to the two metal sheets, wherein each metal sheet has a thickness between 0.015 inch and about 0.1 inch, the thickness of the laminate is less than about 2 inches, and the panel is characterized by having a flexural modulus of at least about 2.5 million psi, by having a core thickness at least equal to the combined thickness of the metal sheets, and by having a weight of no more than about 3 lb/ft 2 .
Claim 7
Dependent Claim
104 words
A freight container body comprising at least one panel which is a structural laminate comprising two metal sheets and a thermoset reinforced resin core between and bonded to the two metal sheets, wherein each metal sheet has a thickness between 0.015 inch and about 0.1 inch, the thickness of the laminate is less than about 2 inches, and the panel is characterized by having a flexural modulus of at least about 2.5 million psi, by having a core thickness at least equal to the combined thickness of the metal sheets, and by having a weight of no more than about 3 lb/ft 2 .
Claim 8
Dependent Claim
23 words
A freight container body according to claim 5 wherein the laminate is characterized by having a rigidity index of at least about 3000.
Claim 9
Dependent Claim
14 words
A freight container body according to claim 5 wherein the metal sheets are aluminum.
Claim 10
Dependent Claim
14 words
A freight container body according to claim 5 wherein the resin core comprises microballoons.
Claim 11
Dependent Claim
101 words
A freight container body comprising at least one panel which is a structural laminate comprising two metal sheets and a thermoset reinforced resin core between and bonded to the two metal sheets, wherein each metal sheet has a thickness between 0.015 inch and about 0.1 inch, the thickness of the laminate is less than about 2 inches, and the panel is characterized by having sufficient impact resistance to pass the falling ball impact test with no delamination of the core and metal sheet or cracking of the core, and characterized by having a shear modulus of at least about 25 ksi.
Claim 12
Dependent Claim
101 words
A freight container body comprising at least one panel which is a structural laminate comprising two metal sheets and a thermoset reinforced resin core between and bonded to the two metal sheets, wherein each metal sheet has a thickness between 0.015 inch and about 0.1 inch, the thickness of the laminate is less than about 2 inches, and the panel is characterized by having sufficient impact resistance to pass the falling ball impact test with no delamination of the core and metal sheet or cracking of the core, and characterized by having a shear modulus of at least about 25 ksi.
Claim 13
Dependent Claim
23 words
A freight container body according to claim 9 wherein the laminate is characterized by having a rigidity index of at least about 3000.
Claim 14
Dependent Claim
14 words
A freight container body according to claim 9 wherein the metal sheets are aluminum.
Claim 15
Dependent Claim
14 words
A freight container body according to claim 9 wherein the resin core comprises microballoons.
Claim 16
Dependent Claim
109 words
A laminate comprising two metal sheets and a reinforced thermoset resin core between and bonded to the metal sheets, wherein each metal sheet has a thickness between about 0.015 inch and about 0.1 inch, the thickness of the laminate is less than about 2 inches, and the thickness of the core is at least equal to the combined thickness of the metal sheets, and wherein the laminate is characterized by having a flexural modulus of at least about 2.5 million psi and by having sufficient impact resistance to pass the falling ball impact test with no delamination of the core and metal sheet and no cracking of the core.
Claim 17
Dependent Claim
109 words
A laminate comprising two metal sheets and a reinforced thermoset resin core between and bonded to the metal sheets, wherein each metal sheet has a thickness between about 0.015 inch and about 0.1 inch, the thickness of the laminate is less than about 2 inches, and the thickness of the core is at least equal to the combined thickness of the metal sheets, and wherein the laminate is characterized by having a flexural modulus of at least about 2.5 million psi and by having sufficient impact resistance to pass the falling ball impact test with no delamination of the core and metal sheet and no cracking of the core.
Claim 18
Dependent Claim
17 words
A laminate according to claim 13 wherein the flexural modulus is at least about 3 million psi.
Claim 19
Dependent Claim
12 words
A laminate according to claim 13 wherein the metal sheets are aluminum.
Claim 20
Dependent Claim
19 words
A laminate according to claim 13 wherein the reinforced resin core has a specific gravity less than about 1.25.
Claim 21
Dependent Claim
21 words
A laminate according to claim 13 wherein the laminate is characterized by having a rigidity index of at least about 3,000.
Claim 22
Dependent Claim
18 words
A laminate according to claim 13 wherein the thickness of the laminate is at least about 0.10 inch.
Claim 23
Dependent Claim
27 words
A laminate according to claim 13 wherein the laminate is characterized by having a tensile yield strength of at least about 2,000 lb. per inch in width.
Claim 24
Dependent Claim
18 words
A laminate according to claim 19 wherein the tensile yield strength is at least about 2,500 lb./in. width.
Claim 25
Dependent Claim
23 words
A laminate according to claim 13 wherein the laminate is characterized by having a core shear modulus of at least about 25 ksi.
Claim 26
Dependent Claim
21 words
A laminate according to claim 21 wherein the laminate is characterized by having a rigidity index of at least about 3,000.
Claim 27
Dependent Claim
77 words
A laminate comprising two metal sheets and a reinforced thermoset resin core between and bonded to the two metal sheets, wherein each metal sheet has a thickness between 0.015 inch and 0.1 inch, the thickness of the laminate is less than about 2 inches, and the thickness of the core is at least equal to the combined thickness of the metal sheets, and the laminate is characterized by having a rigidity index of at least about 3,000.
Claim 28
Dependent Claim
77 words
A laminate comprising two metal sheets and a reinforced thermoset resin core between and bonded to the two metal sheets, wherein each metal sheet has a thickness between 0.015 inch and 0.1 inch, the thickness of the laminate is less than about 2 inches, and the thickness of the core is at least equal to the combined thickness of the metal sheets, and the laminate is characterized by having a rigidity index of at least about 3,000.
Claim 29
Dependent Claim
12 words
A laminate according to claim 23 wherein the metal sheets are aluminum.
Claim 30
Dependent Claim
15 words
A laminate according to claim 23 wherein the rigidity index is at least about 4,000.
Claim 31
Dependent Claim
15 words
A laminate according to claim 23 wherein the rigidity index is at least about 4,500.
Claim 32
Dependent Claim
23 words
A laminate according to claim 23 wherein the laminate is characterized by having a core shear modulus of at least about 25 ksi.
Claim 33
Dependent Claim
18 words
A laminate according to claim 23 wherein the thickness of the laminate is at least about 0.10 inch.
Claim 34
Dependent Claim
67 words
A laminate which comprises two metal sheets and a thermoset resin core between and bonded to the two metal sheets, wherein the metal sheet has a thickness between about 0.040 inch and about 0.070 inch, and wherein the resin core comprises a reinforced thermoset resin and contains a sufficient amount of microballoons to provide a specific gravity of the reinforced resin core is less than about 1.3.
Claim 35
Dependent Claim
67 words
A laminate which comprises two metal sheets and a thermoset resin core between and bonded to the two metal sheets, wherein the metal sheet has a thickness between about 0.040 inch and about 0.070 inch, and wherein the resin core comprises a reinforced thermoset resin and contains a sufficient amount of microballoons to provide a specific gravity of the reinforced resin core is less than about 1.3.
Claim 36
Dependent Claim
12 words
A laminate according to claim 29 wherein the metal sheets are aluminum.
Claim 37
Dependent Claim
113 words
A laminate comprising two metal sheets and a reinforced thermoset resin core between and bonded to the two metal sheets, wherein each metal sheet has a thickness between 0.015 inch and about 0.1 inch, the thickness of the laminate is less than about 2 inches, and the thickness of the core is at least equal to the combined thickness of the metal sheets, and the laminate is characterized by having a shear modulus of the core of at least about 25 ksi wherein the laminate is characterized by having sufficient impact resistance to pass the falling ball impact test with no delamination of the core and metal sheet or cracking of the core.
Claim 38
Dependent Claim
113 words
A laminate comprising two metal sheets and a reinforced thermoset resin core between and bonded to the two metal sheets, wherein each metal sheet has a thickness between 0.015 inch and about 0.1 inch, the thickness of the laminate is less than about 2 inches, and the thickness of the core is at least equal to the combined thickness of the metal sheets, and the laminate is characterized by having a shear modulus of the core of at least about 25 ksi wherein the laminate is characterized by having sufficient impact resistance to pass the falling ball impact test with no delamination of the core and metal sheet or cracking of the core.
Claim 39
Dependent Claim
19 words
A laminate according to claim 31 wherein the shear modulus of the core is at least about 33 ksi.
Claim 40
Dependent Claim
17 words
A laminate according to claim 31 wherein the core shear modulus is at least about 33 ksi.
Claim 41
Dependent Claim
17 words
A laminate according to claim 31 wherein the core shear modulus is at least about 40 ksi.
Claim 42
Dependent Claim
18 words
A laminate according to claim 31 wherein the thickness of the laminate is at least about 0.10 inch.
Claim 43
Dependent Claim
12 words
A laminate according to claim 31 wherein the metal sheets are aluminum.
Claim 44
Dependent Claim
15 words
A laminate according to claim 36 wherein the aluminum surface is anodized with phosphoric acid.
Claim 45
Dependent Claim
82 words
An assembly comprising substantially abutting sandwich panels each having recessed cores along the length of each adjacent edge; an internal splice section, positioned in the two recessed area between the metal sheets of the abutting panels, and extending substantially from the recessed core in the first panel to the recessed core in the second panel; and means for attaching the splice section to a metal sheet of at least two abutting panels and to at least one other splice section overlapping therewith.
Claim 46
Dependent Claim
82 words
An assembly comprising substantially abutting sandwich panels each having recessed cores along the length of each adjacent edge; an internal splice section, positioned in the two recessed area between the metal sheets of the abutting panels, and extending substantially from the recessed core in the first panel to the recessed core in the second panel; and means for attaching the splice section to a metal sheet of at least two abutting panels and to at least one other splice section overlapping therewith.
Claim 47
Dependent Claim
29 words
An assembly according to claim 38 wherein the internal splice section comprises two sections which overlap each other along a line which transverses the adjacent edges of the panels.
Claim 48
Dependent Claim
16 words
An assembly according to claim 38 wherein the means for attachment comprises rivets, screws or bolts.
Claim 49
Dependent Claim
14 words
An assembly according to claim 38 wherein the means for attachment comprises adhesive means.
Claim 50
Dependent Claim
48 words
A laminate comprising two aluminum sheets and a plywood core between and bonded to the aluminum sheets with a thermoset resin wherein the aluminum surface of each sheet is anodized with phosphoric acid or etched with chromic acid or dichromate-sulfuric acid before being bonded to the plywood core.
Claim 51
Dependent Claim
48 words
A laminate comprising two aluminum sheets and a plywood core between and bonded to the aluminum sheets with a thermoset resin wherein the aluminum surface of each sheet is anodized with phosphoric acid or etched with chromic acid or dichromate-sulfuric acid before being bonded to the plywood core.
Claim 52
Independent Claim
119 words
A method of making a laminate comprising placing between two metal sheets having prepared surfaces, a resin composition comprising (a) thermoset resin capable of bonding in neat form to the prepared surfaces of the metal sheets upon curing in neat form to provide a lap shear strength of at least 700 psi, (b) reinforcing material present in an amount between about 3 and about 30 parts by weight based upon the weight of the resin, and (c) microballoons in suspension in the resin present in an amount sufficient to produce the cured reinforced resin composition having a specific gravity less than about 1.3, and curing the resin composition while positioned between and in contact with the two metal sheets.
Claim 53
Independent Claim
119 words
A method of making a laminate comprising placing between two metal sheets having prepared surfaces, a resin composition comprising (a) thermoset resin capable of bonding in neat form to the prepared surfaces of the metal sheets upon curing in neat form to provide a lap shear strength of at least 700 psi, (b) reinforcing material present in an amount between about 3 and about 30 parts by weight based upon the weight of the resin, and (c) microballoons in suspension in the resin present in an amount sufficient to produce the cured reinforced resin composition having a specific gravity less than about 1.3, and curing the resin composition while positioned between and in contact with the two metal sheets.
Claim 54
Dependent Claim
12 words
A laminate according to claim 43 wherein the metal sheets are aluminum.
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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) | 1994-07-08 | 1995-01-07 | 1995-07-09 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-07-08 | 1999-01-07 | 1999-07-09 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-07-08 | 2003-01-07 | 2003-07-09 | $7700.00 | Window Closed / Lapsed |