IN-SITU FOAM CORE PANEL SYSTEMS AND METHOD OF MANUFACTURE
A panel system is recited that includes a first panel having a periphery. The panel includes a first plastic layer having a periphery and a second plastic layer opposed and spaced apart from the first layer. The second layer also has a periphery. The first and second layers define a first cavity therebetween. A first in-situ foam core is disposed in the cavity and has a thermal bond to the first and second plastic layers. The panel is capable of supporting 0.1 to 0.5 lbf/in 2 .
1 . A panel, comprising:
a first plastic layer having a periphery;
a second plastic layer having a region opposed and spaced from the first layer, and a periphery joined to the periphery of the first plastic defining at least one substantially enclosed cavity between the first and second layers; and
a foam core of thermally expandable plastic bead filling the cavity when expanded in situ to create a structural core having a thermal bond with the first and second plastic layers, wherein the panel is capable of supporting 0.1 to 0.5 lbf/in 2 .
2 . The panel of claim 1 , wherein the first and second plastic layers are joined together along, a hinge axis forming a living hinge dividing the cavity into two cavity regions each filed with a foam core to form two panel sections hinged together.
3 . The panel system of claim 1 , wherein the panel comprises a vehicle load floor.
4 . The panel of claim 2 wherein the first and second plastic layers are formed of a plastic material which is flexible and durable enough to be flexed 180 degrees at least 1000 times.
5 . The panel of claim 1 , wherein the panel is a component of a vehicle interior.
6 . The panel of claim 1 , wherein the panel forms an exterior surface of a vehicle.
7 . The panel of claim 1 , wherein the panel forms a table surface or a counter surface.
8 . The panel of claim 1 , wherein the panel comprises a basketball backboard.
9 . The panel of claim 1 , wherein the panel comprises a barricade.
10 . The panel of claim 1 , wherein the panel comprises a scaffold component.
11 . The panel of claim 1 , wherein the panel comprises a housing panel or a kick plate.
12 . The panel of claim 1 , wherein the panel comprises a sound deadening panel.
13 . The panel of claim 4 , wherein the first and second panels are formed of metallocene polyropylene.
14 . A vehicle load floor comprising a panel of claim 4 , wherein on of the panel sections forms a hinged door.
15 . the vehicle load floor of claim 14 wherein the panel has a thickness between 0.5 and 1.0 inches.
16 . The panel of claim 6 forming on of a vehicle roof, engine cover and a fender.
17 . The panel of claim 16 wherein the foam core has an expanded density of 2 to 9 lbs/ft 3 .