Composite panel
View Patent ↗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.
1. 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 the elastomeric spacer with a foamed polymer filler, wherein the foamed polymer filler flows between the outer skin cavity and the frame.
2. The method as claimed in claim 1 further including the step of trimming the outer skin cavity to a desired dimension prior to placing the frame in the outer skin cavity.
3. The method as claimed in claim 1 further including the step of wiping the outer skin cavity with acetone prior to placing the frame in the outer skin cavity.
4. The method as claimed in claim 1 further including the step of coating the outer skin cavity with a ceramic coating.
5. The method as claimed in claim 1 wherein the step of constructing the frame includes welding tubular, steel frame members.
6. The method as claimed in claim 1 wherein the step of forming the outer skin cavity includes vacuum forming an outer skin from acrylonitrile butadiene styrene.
7. The method as claimed in claim 1 wherein the step of filling the area in the outer skin cavity not occupied by the frame or the elastomeric spacer with a foamed polymer filler includes compression filling said area with polyurethane.
8. The method as claimed in claim 1 wherein the step of filling the area in the outer skin cavity not occupied by the frame or the elastomeric spacer with a foamed polymer filler includes compression filling said area with polyurethane having a 3 lb density.