COMPOSITE PANEL

• US 20100101182A1
• Filed: 10/23/2008
• Published: 04/29/2010
• Est. Priority Date: 10/23/2008
• Status: Active Grant

• Current Assignee: OS Management Corp., Phlox Consulting Group Inc.
• Original Assignee: Phlox Consulting Group Inc.
• Inventors: Murchie, John
• Granted Patent: US 8,438,816 B2
• Time in Patent Office: Days
• US Class Current: 52/800.100
• CPC Class Codes: B29D 99/001 Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings articles with hollow walls B29D24/00
• CPC Class Codes: E04C 2/205 of foamed plastics, or of plastics and foamed plastics, optionally reinforced
• CPC Class Codes: E04C 2/521 serving for locating conduits; for ventilating, heating or cooling
• CPC Class Codes: Y10T 156/1052 with cutting, punching, tearing or severing

Abstract

A composite panel comprises an outer skins and an inner core. The inner core includes a frame, an elastomeric material disposed between at least a portion of the frame and the outer skin, and a foamed polymer filler. Also disclosed is a method of manufacturing the same.

Claims

1. A composite panel comprising:

an outer skin; and

an inner core, the inner core including a frame, an elastomeric material disposed between at least a portion of the frame and the outer skin, and a foamed polymer filler.

2. The composite panel as claimed in claim 1 wherein the frame includes tubular frame members.

3. The composite panel as claimed in claim 1 wherein the frame is a steel frame.

4. The composite panel as claimed in claim 1 wherein the outer skin is formed from acrylonitrile butadiene styrene.

5. The composite panel as claimed in claim 1 wherein the foamed polymer filler is polyurethane.

6. The composite building panel as claimed in claim 1 further including a ceramic coating on the outer skin.

8. The composite building panel as claimed in claim 1 further including a ceramic coating on the outer skin.

7. A composite panel comprising:

a acrylonitrile butadiene styrene outer skin; and

an inner core, the inner core including a steel frame having tubular frame members, disposed between at least a portion of the frame and the outer skin, and a polyurethane filler.

9. A method of manufacturing a composite panel comprising the steps of:

constructing a frame;

constructing an outer skin cavity to receive the frame;

securing an elastomeric spacer to the outer skin cavity;

securing the frame to the elastomeric spacer; and

filling the area in the outer skin cavity not occupied by the frame or elastomeric spacer with a foamed polymer filler.

10. The method as claimed in claim 9 further including the step of trimming the outer skin cavity to a desired dimension prior to placing the frame in the outer skin cavity.

11. The method as claimed in claim 9 further including the step of wiping the outer skin cavity with acetone prior to placing the frame in the outer skin cavity.

12. The method as claimed in claim 9 further including the step of coating at the outer skin cavity with a ceramic coating.

13. The method as claimed in claim 9 wherein the step of constructing the frame includes welding tubular, steel frame members.

14. The method as claimed in claim 9 wherein the step of forming the outer ski cavity includes vacuum forming the outer skins from acrylonitrile butadiene styrene.

15. The method as claimed in claim 9 wherein the step filling the area in the outer skin cavity not occupied by the frame or elastomeric spacer with a foamed polymer filler includes compression filling said area with polyurethane.

16. The method as claimed in claim 9 wherein the step filling the area in the outer skin cavity not occupied by the frame or elastomeric spacer with a foamed polymer filler includes compression filling said area with polyurethane having a 3 lb density.