STRUCTURAL POLYMER CORE ASSEMBLY, METHOD OF MANUFACTURE AND METHOD OF USE
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Accused Products
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.
30 Citations
61 Claims
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1. -46. (canceled)
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47. A method of manufacturing a structural composite, the method comprising:
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preheating a sheet of thermoplastic polymer; continuously feeding said preheated sheet of thermoplastic polymer into a forming apparatus comprised of two opposing portions, each opposing portion having respective raised areas configured to intermesh when said two opposing portions are brought together; forming said sheet into a structural core with a pyramidal geometric pattern repeated along a length and a width thereof; attaching a first reinforcement layer constructed of a polymer onto a top of said structural core; and attaching a second reinforcement layer constructed of a polymer onto a bottom of said structural core. - View Dependent Claims (48, 49, 50, 51, 52, 53, 54, 55, 56)
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57. A method of manufacturing a multi-layer structural composite, the method comprising:
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preheating a sheet of thermoplastic polymer; continuously feeding said preheated sheet of thermoplastic polymer onto a forming apparatus comprised of an array of raised areas situated on a single, one-sided surface; forming said sheet into a structural core with a pyramidal geometric pattern repeated along a length and a width thereof by way of assisted molding; attaching a first reinforcement layer constructed of a polymer onto the top of said structural core; and attaching a second reinforcement layer constructed of a polymer onto the bottom of said structural core.
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58. A method of manufacturing a multi-layer composite structure having a width, length, and height, the method comprising:
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heating a sheet of fiber-infused thermoplastic polymer; forming said heated sheet of fiber-infused thermoplastic polymer into a structural core having a pyramidal geometric pattern, wherein said pyramidal geometric pattern repeats along a length and a width of said structural core, is symmetric about a neutral axis of said structural core, and is comprised of a plurality of pyramidal shapes, and wherein each of said pyramidal shapes has at least four side-faces intersecting at respective edges, each of said edges including a radius; thermally bonding a first thermoformable reinforcement layer to a top of said structural core, said first reinforcement layer being constructed of the same fiber-infused thermoplastic polymer as said structural core; and thermally bonding a second thermoformable reinforcement layer to a bottom of said structural core, said second reinforcement layer being constructed of the same fiber-infused thermoplastic polymer as said structural core. - View Dependent Claims (59, 60, 61)
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Specification