Composite panel

• US 8,438,816 B2
• Filed: 10/23/2008
• Issued: 05/14/2013
• Est. Priority Date: 10/23/2008
• Status: Expired due to Fees

• Current Assignee: OS Management Corp., Phlox Consulting Group Inc.
• Original Assignee: Phlox Consulting Group Inc.
• Inventors: Murchie, John
• Primary Examiner(s): Glessner, Brian
• Assistant Examiner(s): FIGUEROA, LUZ ADRIANA
• Application Number:
  US12/257,231
• Publication Number:
  US 20100101182A1
• Time in Patent Office: 1,664 Days
• Field of Search: 523/094, 523/097, 523/099, 523/091.6, 527/841, 527/84, 52/15, 527/941, 524/071, 52677-689, 428/71
• US Class Current: 52/794.1
• 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, a plurality of elastomeric spacers maintaining a spacing between the frame and the outer skin, and a foamed polymer filler between the frame and the outer skin;

wherein the foamed polymer filler is set around the elastomeric spacers so there is no air gap between the frame and the outer skin and the elastomeric spacers minimize forces exerted on the outer skin as the frame undergoes thermal expansion.

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.

9. The composite building panel as claimed in claim 1 wherein the elastomeric spacers are secured to the outer skin.

11. A building comprising the composite panel of claim 1.

7. A composite panel comprising:

an acrylonitrile butadiene styrene outer skin; and

an inner core, the inner core including a steel frame having tubular frame members, a plurality of elastomeric spacers maintaining a spacing between the frame and the outer skin, and a polyurethane filler between the frame and the outer skin;

wherein the polyurethane filler is set around the elastomeric spacers so there is no air gap between the frame and the outer skin and the elastomeric spacers minimize forces exerted on the outer skin as the frame undergoes thermal expansion.

8. The composite building panel as claimed in claim 7 further including a ceramic coating on the outer skin.

10. The composite building panel as claimed in claim 7 wherein the elastomeric spacers are secured to the outer skin.