Structural polymer core assembly, method of manufacture and...

Stock material or miscellaneous articles – Structurally defined web or sheet – Nonplanar uniform thickness material

Reexamination Certificate

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Details

C428S137000, C428S138000, C428S180000, C296S214000, C181S288000, C181S290000, C181S292000, C052S789100, C052S793100

Reexamination Certificate

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10352803

ABSTRACT:
A composite structure, and method of manufacturing it, having a specified width, length, and height defining a top and bottom the composite structure. The composite structure includes a three dimensional structural core constructed of a polymer with a first series of a geometric pattern repeated along its length. The structural core also has a second series of the geometric pattern repeated along the width thereof. The geometric patter may be a sinusoidal curve or a substantially pyramidal shape. The composite structure also includes a first reinforcement layer made of a polymer positioned above the structural core and bonded thereto. It also includes a second reinforcement layer made of a polymer that is positioned below the structural core and bonded thereto. The composite structure may also include a decorative layer above the first reinforcement layer, an acoustical batting layer positioned between the first reinforcement layer and the structural core, and may include fire retardant chemicals.

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