Molded high impact industrial door
First Claim
1. An impact resistant industrial door, comprising a honeycomb core formed of thermoplastic resin and having a pair of opposed faces and having edges connecting said faces, said core having a multiplicity of cells with each cell having an open end and having a closed bottom, the open ends of a first group of said cells being located on one face and the open ends of a second group of said cells being located on the opposite face, a lightweight resilient flexible material filling said cells and extending to said open ends, an elastomeric resin encapsulating said core and being bonded to said faces and said edges and to said material exposed in the open end of said cells, said core having a plurality of holes extending between said faces and intersecting said cells, and said elastomeric resin extending through said holes.
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Accused Products
Abstract
A molded, high impact, industrial door having a thermoplastic resin honeycomb core formed with a multiplicity of cells. Each cell has an open end and side walls that converge to a closed bottom and alternate cells open to opposite faces of the core. The cells are filled with a lightweight resilient flexible filler material, such as foam resin, and the core is encapsulated in an elastomeric resin. The molded door is abrasion and corrosion resistant and is capable of withstanding the high impact forces of material handling equipment.
42 Citations
16 Claims
- 1. An impact resistant industrial door, comprising a honeycomb core formed of thermoplastic resin and having a pair of opposed faces and having edges connecting said faces, said core having a multiplicity of cells with each cell having an open end and having a closed bottom, the open ends of a first group of said cells being located on one face and the open ends of a second group of said cells being located on the opposite face, a lightweight resilient flexible material filling said cells and extending to said open ends, an elastomeric resin encapsulating said core and being bonded to said faces and said edges and to said material exposed in the open end of said cells, said core having a plurality of holes extending between said faces and intersecting said cells, and said elastomeric resin extending through said holes.
- 7. An industrial door, comprising a honeycomb core formed of thermoplastic resin and having a pair of exposed faces and having side edges connecting said faces, said core composed of a multiplicity of cells with each cell having an open end and a closed bottom, the open ends of a first group of said cells being located on one of said faces while the open ends of a second group of said cells being located on said opposite face, a lightweight resilient flexible material bonded with and filling the cells and extending to said open ends, and a tough impact resistant plastic material molded around said core and being bonded to said faces and to said side edges and to said material exposed at the open ends of said cells, said core having a plurality of holes extending through said core from one face to the opposite face and intersecting said cells, said plastic material disposed within said holes.
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9. An industrial door, comprising a honeycomb core formed of thermoplastic resin and having a pair of exposed faces and having side edges connecting said faces, said core composed of a multiplicity of cells with each cell having an open end and a closed bottom, the open ends of a first group of said cells being located on one of said faces while the open ends of a second group of said cells being located on said opposite face, said cells being disposed in a regular pattern throughout said core, a foam resin material disposed within said cells and extending to said open ends, a reinforcing sheet having a plurality of openings and disposed on at least one of said faces, a plurality of generally cylindrical holes extending through said core between said faces and intersecting said cells, said holes cutting through the walls of said cells, and an elastomeric resin molded around the core and bonded to said faces and said edges and to said material exposed in the open ends of said cells, said elastomeric resin extending through said holes.
- 10. A method of fabricating an industrial door, comprising the steps of forming a thermoplastic resin honeycomb core composed of a pair of opposed faces connected by side edges, said core having a multiplicity of cells with each cell having an open end and a closed bottom, the open ends of a first group of said cells being located on one of said faces and the open ends of a second group of said cells being located on said opposite face, introducing a lightweight resilient material into said cells to fill the cells to said open ends, and encapsulating said core in an impact resistant thermoplastic resin to enclose said faces and said side edges in said resin.
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16. An industrial door, comprising a honeycomb core formed of thermoplastic resin and having a pair of exposed faces and having side edges connecting said faces, said core composed of a multiplicity of cells with each cell having an open end and a closed bottom, the open ends of a first group of said cells being located on one of said faces while the open ends of a second group of said cells being located on said opposite face, a lightweight resilient flexible material bonded with and filling the cells and extending to said open ends, a tough impact resistant plastic material molded around said core and being bonded to said face and to said side edges and to said material exposed at the open ends of said cells, and a flexible wiper strip integrally molded with said plastic material and extending laterally from at least one of said side edges.
Specification