Panel and method of making the same

Details Panel and method of making the same Panel and method of making the same

1988-02-26

1992-02-18

Gallagher, John J.

Stock material or miscellaneous articles

Web or sheet containing structurally defined element or...

Composite having voids in a component

156 90, 156285, 1563066, 1563069, 1563073, 156313, 296214, 428247, 4283166, 4283177, B32B 514, B32B 3300

Patent

active

050893289

ABSTRACT:
A method of making a lightweight panel having a relatively soft foam-backed cover sheet supported on a relatively hard, self-supporting core in one simple step. An assembly of foam layers is built up comprising a core-forming foam layer, an intermediate foam layer, and a cover-backing foam layer, with a scrim sheet over the core-forming foam layer and a cover sheet over the cover-backing foam layer. The core-forming layer is impregnated with a heat-activatable hardening compound. The intermediate layer as well as the cover-backing layer may also, if desired, be impregnated with a heat-activatable hardening compound but usually in lesser amounts. The hardening compound coats the cell walls of the foam. The panel is formed by subjecting this layered assembly to heat and pressure between contoured dies in a single compression molding operation at a temperature at which the hardening compound is activated. The layers of the assembly are bonded together either by the hardening compound or by thermoplastic films placed between layers which are melted by the heat of the molding operation and become adhesive when melted.

REFERENCES:
patent: 3193440 (1965-07-01), Schafer
patent: 3264166 (1966-08-01), Lowery
patent: 3825642 (1974-07-01), Kies
patent: 3829343 (1974-08-01), Remmert
patent: 4042751 (1977-08-01), Roth
patent: 4119749 (1978-10-01), Roth et al.

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