Method of manufacturing a metal-reinforced plastic panel

• US 20040026021A1
• Filed: 06/02/2003
• Published: 02/12/2004
• Est. Priority Date: 05/31/2002
• Status: Abandoned Application

• Current Assignee: Crane Plastics Company LLC
• Original Assignee: Crane Plastics Company LLC
• Inventors: Frechette, John P., Groh, A. Anthony, Burt, Kevin T., Fenneman, Matthew T.
• Application Number:
  US10/452,612
• Publication Number:
  US 20040026021A1
• Time in Patent Office: Days
• US Class Current: 156/244.12
• CPC Class Codes: B29C 48/07 Flat, e.g. panels
• CPC Class Codes: B29C 48/12 Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• CPC Class Codes: B29C 48/15 incorporating preformed parts or layers, e.g. extrusion moulding around inserts
• CPC Class Codes: B29C 48/154 Coating solid articles, i.e. non-hollow articles
• CPC Class Codes: B29C 53/043 using rolls or endless belts
• CPC Class Codes: B32B 1/00 Layered products having a non-planar shape
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 15/18 comprising iron or steel B32B15/011, B32B15/012 and B32B15/013 take precedence
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 37/153 at least one layer is extruded and immediately laminated while in semi-molten state
• CPC Class Codes: E02D 5/03 Prefabricated parts , e.g. composite sheet piles
• CPC Class Codes: E02D 5/74 Means for anchoring structural elements or bulkheads anchoring piles E02D5/54 ; anchored foundations E02D27/50

Abstract

A composite panel comprised of a sheet of substrate and a coextruded layer of plastic covering the substrate. The panel may be used as a retaining panel for a body of water in a cantilever wall or an anchored sheet pile wall. The retaining panel may include a central portion, two side portions, and two flanges. The retaining panel may also include integral connecting portions. The substrate may be comprised of a material such as aluminum or steel, while the plastic may be a material such as polyvinyl chloride (PVC). Other applications of the composite panel include uses as building panels for sidewalls or roofs.

Claims

1. A method of manufacturing a panel, said method comprising:

providing a metal sheet to an extrusion system;

extruding a plastic on said metal sheet to form an extrudate; and

roll forming said extrudate into a final shape of said panel.

2. The method of claim 1 wherein said extrusion system comprises at least one die.

3. The method of claim 1 wherein said metal sheet is comprised of a metal selected from the group consisting of steel and aluminum.

4. The method of claim 1 wherein said metal sheet is flat when applied to said extrusion system.

5. The method of claim 1 wherein said plastic comprises polyvinyl chloride.

6. The method of claim 1 wherein said plastic is a plastic composite.

7. The method of claim 6 wherein said plastic composite comprises a cellulosic filler.

8. The method of claim 6 wherein said plastic composite comprises an inorganic filler.

9. The method of claim 1 wherein said panel comprises:

a central portion having a first end portion and a second end portion;

a first side portion extending rearwardly from said first end portion of said central portion; and

a second side portion extending rearwardly from said second end portion of said central portion.

10. The method of claim 9 wherein said panel further comprises:

a first flange extending from a rear end portion of said first side portion; and

a second flange extending from a rear end portion of said second side portion.

11. The method of claim 10 wherein:

a distal portion of said first flange comprises a female connecting portion; and

a distal portion of said second flange comprises a male connecting portion.

12. A method of manufacturing a panel, said method comprising:

providing a flat metal sheet;

extruding a plastic on all sides of said metal sheet to form an extrudate; and

roll forming said extrudate into said panel, said panel having a generally U-shaped portion.

13. The method of claim 12 wherein said metal sheet is comprised of a metal selected from the group consisting of steel and aluminum.

14. The method of claim 12 wherein said plastic comprises polyvinyl chloride.

15. The method of claim 12 wherein said plastic is a plastic composite.

16. The method of claim 15 wherein said plastic composite comprises a cellulosic filler.

17. The method of claim 15 wherein said plastic composite comprises an inorganic filler.

18. A method of manufacturing a panel, said method comprising:

providing a flat metal sheet;

coating a plastic on all sides of said metal sheet; and

roll forming said metal sheet such that a final shape of said panel is formed, said panel having a generally U-shaped portion.

19. The method of claim 18 wherein said panel is a seawall panel.

20. The method of claim 18 wherein plastic is coated on said metal sheet by extrusion.