Stock material or miscellaneous articles – Structurally defined web or sheet – Honeycomb-like
Patent
1987-09-30
1989-01-10
Van Balen, William J.
Stock material or miscellaneous articles
Structurally defined web or sheet
Honeycomb-like
264 453, 264 464, 264 465, 264 466, 428 71, 4283099, 4283166, 441 74, B32B 104, B32B 302, A63C 1505
Patent
active
047973129
ABSTRACT:
A surface-reinforced lightweight article is described, which includes a honeycomb structure whose sidewalls are reinforced by an expanded foam. The article can be manufactured by laying a fibrous third layer, such as several layers of dry tissue paper backed by a layer of dry fiberglass cloth, on the walls of a mold, laying a second layer of multi-cell honeycomb-like material against the third layer, and laying a finely porous first layer such as tissue paper over the second layer. Foamable plastic is poured in the mold over the three layers and the mold is closed. As the plastic foams and expands, it forces the three layers into a tight sandwich and permeates the layers to reinforce them. Specifically, expanded foam in the cells of multi-cell honeycomb-type material braces the honeycomb sidewalls against collapse, to greatly increase the strength and rigidness of the article. It is found that the density of foam is much greater in the cells than in the core of the article that lies inside the layers, so that high strength foam lies where it is needed while keeping the core lightweight.
REFERENCES:
patent: 3543315 (1970-12-01), Hoffman
patent: 4330494 (1982-05-01), Iwata et al.
patent: 4379103 (1983-04-01), Doerfling
patent: 4510105 (1985-04-01), Sherwood
patent: 4664974 (1987-05-01), Sherwood
patent: 4687691 (1987-08-01), Kay
patent: 4753836 (1988-06-01), Mizell
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