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

• US 20040081797A1
• Filed: 01/28/2003
• Published: 04/29/2004
• Est. Priority Date: 01/28/2002
• Status: Active Grant

• Current Assignee: Innovative Composites, Inc. (Innovative Composites International, Inc.)
• Original Assignee: Richard A. Simmons
• Inventors: Stoll, John R., Panik, Keith, Simmons, Richard A., Simmons, F. Arthur
• Granted Patent: US 7,297,390 B2
• Time in Patent Office: Days
• US Class Current: 428/137
• CPC Class Codes: B32B 3/28 characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: Y10T 156/1039 Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 428/24322 Composite web or sheet
• CPC Class Codes: Y10T 428/24331 including nonapertured component
• CPC Class Codes: Y10T 428/24661 Forming, or cooperating to form cells
• CPC Class Codes: Y10T 428/24678 Waffle-form
• CPC Class Codes: Y10T 428/24694 Parallel corrugations

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.

Claims

1. A composite structure having a specified width, length, and height defining a top and bottom of said composite structure comprising:

a three dimensional structural core constructed of a polymer with a first series of a geometric pattern repeated along the length thereof and a second series of said geometric pattern repeated along the width thereof;

a first reinforcement layer positioned above said structural core and bonded thereto wherein said first reinforcement layer is constructed of a polymer, and

a second reinforcement layer positioned below said structural core and bonded thereto wherein said second reinforcement layer is constructed of a polymer.

2. The composite structure of claim 1 further comprising:

a decorative layer positioned above said first reinforcement layer and bonded thereto.

3. The composite structure of claim 1 further comprising:

an acoustical batting layer positioned between said first reinforcement layer and said structural core.

4. The composite structure of claim 1 wherein said structural core is constructed of a polymer infused with fiber.

5. The composite structure of claim 1 wherein said first and second reinforcement layers contain openings along the length and width thereof.

6. The composite structure of claim 1 wherein at least one component therein includes fire retardant chemicals.

7. The composite structure of claim 1 wherein said structural core and said first and second reinforcement layers are constructed of a translucent polymer.

8. The composite structure of claim 1 wherein said geometric pattern is substantially a sinusoidal curve.

9. The composite structure of claim 1 wherein said geometric pattern is substantially a pyramidal shape.

10. An automotive headliner composite structure having a specified width, length, and height defining a top and bottom of said automotive headliner composite structure comprising:

a three dimensional structural core constructed of a polymer with a first series of a geometric pattern repeated along the length thereof and a second series of said geometric pattern repeated along the width thereof;

a first reinforcement layer positioned above said structural core and bonded thereto wherein said first reinforcement layer is constructed of a polymer,

a second reinforcement layer positioned below said structural core and bonded thereto wherein said second reinforcement layer is constructed of a polymer; and

a decorative layer positioned above said first reinforcement layer and bonded thereto.

11. The automotive headliner composite structure of claim 10 wherein said structural core is constructed of a polymer infused with fiber.

12. The automotive headliner composite structure of claim 11 further comprising:

an acoustical batting layer positioned between said first reinforcement layer and said structural core.

13. The automotive headliner composite structure of claim 11 further comprising:

an acoustical batting layer positioned between said second reinforcement layer and said structural core.

14. The automotive headliner composite structure of claim 10 wherein at least one component therein includes fire retardant chemicals.

15. The automotive headliner composite structure of claim 10 wherein at least one of said first and second reinforcement layers contain repeated openings along the length and width thereof.

16. The automotive headliner composite structure of claim 10 wherein said geometric pattern is substantially a sinusoidal curve.

17. The automotive headliner composite structure of claim 10 wherein said geometric pattern is substantially a pyramidal shape.

18. A method of utilizing a composite structure having a specified width, length, and height defining a top and bottom of said composite structure comprising:

providing a three dimensional structural core constructed of a polymer with a first series of a geometric pattern repeated along the length thereof and a second series of said geometric pattern repeated along the width thereof;

bonding a first reinforcement layer to the top of said structural core wherein said first reinforcement layer is constructed of a polymer; and

bonding a second reinforcement layer to the bottom of said structural core wherein said second reinforcement layer is constructed of a polymer.

19. The method of claim 18 wherein said geometric pattern is substantially a sinusoidal curve.

20. The method of claim 19 further comprising:

using said composite structure as a component of an automotive interior.

21. The method of claim 19 further comprising:

using said composite structure as a load bearing portion of a stationary structure.

22. The method of claim 19 further comprising:

using said composite structure as a door.

23. The method of claim 19 further comprising:

using said composite structure to construct at least a portion of a marine vehicle.

24. The method of claim 19 further comprising:

using said composite structure as a component of an aircraft interior.

25. The method of claim 19 further comprising:

using said composite structure as a cooking sheet.

26. The method of claim 19 further comprising:

treating at least a portion of said composite structure with fire retardant chemicals.

27. The method of claim 26 further comprising:

using said composite structure as a component of a piece of furniture.

28. The method of claim 19 further comprising:

placing a layer of acoustical batting between said structural core and said first reinforcement layer.

29. The method of claim 28 further comprising:

using said composite structure as a sound absorption panel.

30. The method of claim 29 wherein at least one of said first and second reinforcing layers contains repeated openings along the length and width thereof.

31. The method of claim 18 wherein said geometric pattern is substantially a pyramidal shape.

32. The method of claim 31 further comprising:

using said composite structure as a component of an automotive interior.

33. The method of claim 31 further comprising:

using said composite structure as a load bearing portion of a stationary structure.

34. The method of claim 31 further comprising:

using said composite structure as a door.

35. The method of claim 31 further comprising:

using said composite structure to construct at least a portion of a marine vehicle.

36. The method of claim 31 further comprising:

using said composite structure as a component of an aircraft interior.

37. The method of claim 31 further comprising:

using said composite structure as a cooking sheet.

38. The method of claim 31 further comprising:

treating at least a portion of said composite structure with fire retardant chemicals.

39. The method of claim 38 further comprising:

using said composite structure as a component of a piece of furniture.

40. The method of claim 31 further comprising:

placing a layer of acoustical batting between said structural core and said first reinforcement layer.

41. The method of claim 40 further comprising:

using said composite structure as a sound absorption panel.

42. The method of claim 41 wherein at least one of said first and second reinforcing layers contains repeated openings along the length and width thereof.

43. A method of manufacturing a structural composite for use in the interior of a vehicle comprising:

providing a sheet of polymer;

preheating said sheet of polymer;

forming said sheet of polymer into a structural core with a first series of a geometric pattern repeated along the length thereof and a second series of said geometric pattern repeated along the width thereof by way of compression;

laminating a first reinforcement layer constructed of a polymer onto the top of said structural core;

laminating a second reinforcement layer constructed of a polymer onto the bottom of said structural core;

affixing a decorative layer to the outer portion of said first reinforcement layer; and

forming said structural composite into the shape for which it will be used in said interior of said vehicle.

44. The method of claim 43 further comprising:

positioning a layer of acoustical batting between said structural core and one of said first and second reinforcement layers.

45. The method of claim 43 further comprising:

designing said geometric pattern with the assistance of a computer to have specific mechanical properties.

46. The method of claim 43 wherein said sheet of polymer is infused with fibrous material.