Composite structural panel
First Claim
Patent Images
1. A composite structural panel comprising:
- a first sheet including a first outer surface and a first inner surface;
a second sheet spaced apart from the first sheet and including a second outer surface and a second inner surface;
a stiffening core element disposed between the first and second sheets and defining a plurality of cells; and
a rigid foam reinforcing material disposed in the cells.
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Accused Products
Abstract
An improved composite structural panel and method of fabrication are provided. In one embodiment, the panel generally includes two outer layers or sheets arranged in substantially facing relationship to each other and an intermediate layer spacing the outer layers apart. The intermediate layer includes a generally rigid stiffening or reinforcing core that preferably is bonded to outer layers to form a unified composite structure. In one embodiment, the core has an open structure defining a plurality of open cells 15. An insulating material is preferably disposed in the cells, and in one embodiment is a rigid foam that structurally reinforces the core 14 and strengthens the panel.
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Citations
30 Claims
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1. A composite structural panel comprising:
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a first sheet including a first outer surface and a first inner surface;
a second sheet spaced apart from the first sheet and including a second outer surface and a second inner surface;
a stiffening core element disposed between the first and second sheets and defining a plurality of cells; and
a rigid foam reinforcing material disposed in the cells. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A composite structural panel comprising:
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a first facing sheet;
a second facing sheet spaced apart from the first sheet;
a foam material disposed between the first and second sheets; and
a first longitudinally-extending edge having a deformable foam portion protruding outwards from the edge and extending longitudinally along the first edge, wherein the deformable portion of the first edge is compressible in response to contact by an abutting surface. - View Dependent Claims (13, 14, 15, 16, 17, 18)
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19. A composite structural panel system comprising:
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a first panel including an internal cavity, an insulating material disposed in the cavity, and a first longitudinally-extending edge having a deformable foam portion protruding outwards from the edge and extending longitudinally along the first edge; and
a second panel including a second longitudinally-extending edge configured to complement the first edge and receive the first edge in an interlocking relationship;
wherein the deformable portion of the first edge compresses upon contact with the second edge when the second edge is inserted into the first edge. - View Dependent Claims (20, 21, 22)
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23. A modular structural panel system comprising:
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a first panel including a pair of spaced apart sheets each having an outer face and at least one first edge longitudinally-extending between the sheets, the edge including an elongated recess and an elongated projection extending along the edge;
a second panel including a pair of spaced apart sheets each having an outer face and at least one second edge longitudinally-extending between the sheets, the second edge including an elongated recess and an elongated projection extending along the second edge, the second edge being complementary to the first edge;
the first and second edges abuttingly interconnected such that the projection of the first edge complementary engages the recess of the second edge and vice-versa to define a joint, the joint including a pressure equalization chamber to balance ambient pressures on opposite faces of the first and second panels. - View Dependent Claims (24)
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25. A method of producing a composite structural panel comprising:
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applying a thickness of foam to a first sheet held in a substantially horizontal position;
setting a core having open cells down into the foam;
contacting the core with the first sheet;
layering a second sheet onto the core to form a panel; and
expanding the foam between the first and second sheets to reinforce to the core. - View Dependent Claims (26, 27, 28, 29, 30)
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Specification