US20120040131A1 - Composite Panel Having Perforated Foam Core - Google Patents

Abstract

A composite panel configured for use with a sidewall of a trailer includes an outer metal sheet, an inner metal sheet, and a core member positioned between the inner and outer metal sheets. The core member includes a plurality of apertures formed therethrough such that each aperture extends from an inner surface of the core member to an outer surface of the core member. Illustratively, the plurality of apertures is covered by the inner and outer metal sheets.

Description

• This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 61/372,259 entitled OVERHEAD DOOR ASSEMBLY FOR A STORAGE CONTAINER and filed Aug. 10, 2010, the entirety of which is hereby incorporated by reference herein.
FIELD OF THE INVENTION
• The present invention relates generally to a composite panel for a storage container, such as a truck trailer, for example. In particular, the present invention relates to a perforated foam core of the composite panel.
BACKGROUND
• Many storage containers, such as large truck trailers, for example, include sidewalls made from composite panels. Illustratively, such composite panels may include a plastic core member sandwiched between thin metal skins. The composite panels are thereafter joined together to create the trailer sidewall. For example, DURAPLATE® composite panels provided by Wabash National Corporation of Lafayette, Ind. are constructed of a high-density polyethylene plastic core bonded between two high-strength steel skins.
SUMMARY
• The present invention may comprise one or more of the features recited in the attached claims, and/or one or more of the following features and combinations thereof.
• According to one aspect of the present disclosure, a composite panel configured for use with a sidewall of a trailer includes an outer metal sheet, an inner metal sheet, and a core member positioned between the inner and outer metal sheets. The core member includes a plurality of apertures formed therethrough such that each aperture extends from an inner surface of the core member to an outer surface of the core member. The plurality of apertures is covered by the inner and outer metal sheets and wherein a length and width of each aperture is less than a respective length and width of the core member.
• In one illustrative embodiment, the plurality of apertures may be circular in shape. Illustratively, a diameter of each aperture may be in the range of approximately ¼ inch to ½ inch.
• In another illustrative embodiment, the composite panel may further include an adhesive between the inner metal sheet and the core member and between the outer metal sheet and the core member.
• In still another illustrative embodiment, the plurality of apertures may include a plurality of adjacent vertical rows of apertures that are aligned with each other and a plurality of adjacent horizontal rows of apertures that are aligned with each other.
• In yet another illustrative embodiment, the plurality of apertures may include a plurality of adjacent vertical rows of apertures that are offset from each other and a plurality of adjacent horizontal rows of apertures that are offset from each other.
• In still another illustrative embodiment, a top-most horizontal row of apertures may be spaced-apart from a top edge of the core member. Illustratively, a vertical distance between the top edge of the core member and a center of the top-most horizontal row of apertures may be between approximately 0.50-6.00 inches. More particularly, the vertical distance may be approximately 2.0 inches.
• In yet another illustrative embodiment, a left-most vertical row of apertures may be spaced-apart from a left side edge of the core member. Illustratively, a horizontal distance between the left side edge of the core member and a center of the left-most vertical row of apertures may be between approximately 0.50-6.00 inches. More particularly, the horizontal distance may be approximately 6.0 inches.
• In still another illustrative embodiment, a top-most horizontal row of apertures may be spaced-apart a first distance from a top edge of the core member. Further illustratively, a left-most vertical row of apertures may be spaced-apart a second distance from a left side edge of the core member. The first distance may be smaller than the second distance.
• In yet another illustrative embodiment, the apertures may be generally uniformly spaced-apart from one another.
• In still another illustrative embodiment, the apertures may be generally similarly-sized.
• In yet another illustrative embodiment, the core member may be a foamed core member including a plurality of air bubbles therein.
• In still another illustrative embodiment, none of the plurality of apertures may be open to any one of a top, bottom, or side edge of the core member.
• In yet another illustrative embodiment, the plurality of apertures may include a plurality of vertically-spaced apart apertures and a plurality of horizontally spaced-apart apertures.
• According to another aspect of the present disclosure, a sidewall of a trailer includes a first composite panel and a second composite panel. The first composite panel includes (i) a first outer metal sheet, (ii) a first inner metal sheet, and (iii) a first core member positioned between the first inner and first outer metal sheets. The first core member includes a first plurality of apertures which are both vertically and horizontally spaced-apart from each other. Each of the first plurality of apertures extends from an inner surface of the first core member to an outer surface of the first core member. The first plurality of apertures is covered by the first inner and first outer metal sheets. The first core member includes a first aperture-free side portion. The second composite panel includes (i) a second outer metal sheet, (ii) a second inner metal sheet, and (iii) a second core member positioned between the second inner and second outer metal sheets. The second core member includes a second plurality of apertures which are both vertically and horizontally spaced-apart from each other. Further, each of the second plurality of apertures extends from an inner surface of the second core member to an outer surface of the second core member. Illustratively, the second plurality of apertures is covered by the second inner and second outer metal sheets and the second core member includes a second aperture-free side portion. The sidewall of the trailer further includes a wall joint coupling the first and second composite panels to each other. The wall joint includes a plurality of fasteners received through the first and second aperture-free portions of the first and second composite panels.
• According to yet another aspect of the present disclosure, a method of forming a composite panel configured for use in a sidewall of a trailer includes forming an uncooled thermal plastic sheet of material and advancing the uncooled thermal plastic sheet of material through a transversing punch. Advancing the uncooled thermal plastic sheet of material through the transversing punch forms apertures through the uncooled thermal plastic sheet of material such that each aperture extends from an outer surface of the thermal plastic sheet of material to an inner surface of the thermal plastic sheet of material. The method further includes cooling the transversing punch and coupling an outer metal sheet and an inner metal sheet to the respective outer surface and the inner surface of the uncooied thermal plastic sheet of material.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a perspective view of a trailer having sidewalls including a plurality of composite panels.
• FIG. 2 is a perspective view of a portion of one of the composite panels ofFIG. 1 showing two outer metal skins and an inner foam core of the panel.
• FIG. 3 is a perspective, exploded view of the composite panel ofFIG. 2 showing the foam core including a plurality of holes formed therethrough.
• FIG. 4 is a planar view of the foam core ofFIG. 3.
• FIG. 5 is a planar view of an alternative foam core.
• FIG. 6 is a schematic of a first method of making the composite panelFIG. 2.
• FIG. 7 is a schematic of a second method of making the composite panel ofFIG. 2.
• FIG. 8 is a schematic of a third method of making of a composite panel having the foam core ofFIG. 5.
• FIG. 9 is a schematic of a fourth method of making a composite panel having an alternative foam core.
• FIG. 10 is a schematic of a fifth method of making a composite panel having an alternative foam core.
• FIG. 11 is a planar view of an alternative foam core.
• FIG. 12 is a perspective view of a portion of two adjacent composite panels of a sidewall of a trailer which are coupled to each other via a coupling joint and which include the alternative foam core ofFIG. 11.
• FIG. 13 is a sectional view of a portion of two adjacent composite panels of a sidewall of a trailer which are coupled to each other via a shiplap joint and which include the alternative foam core ofFIG. 11.
DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
• For the purposes of promoting an understanding of the principles of the invention, reference will now be made to illustrative embodiments shown in the attached drawings and specific language will be used to describe the same. While the concepts of this disclosure are described in relation to a truck trailer, it will be understood that they are equally applicable to other mobile or stationary storage containers, as well as refrigerated and un-refrigerated trailers or storage containers.
• Looking first toFIGS. 1-3, atruck trailer10 includes aroof assembly12 coupled toopposite sidewalls16, a frontend wall assembly18, and a rear end wall assembly (not shown) including an overhead door. Alternatively, the rear end wall assembly may include two rear doors mounted in a conventional manner such that the doors are is hingedly coupled to and swing relative to a rear frame between opened and closed positions. Illustratively, thetrailer10 also includes a floor assembly (not shown) spaced apart from theroof assembly12. Further illustratively, thetrailer10 is connected to a tractor20 by conventional means, such as a fifth wheel, for example.
• Illustratively, eachsidewall16 and thefront end wall18 of thetrailer10 are made from a plurality ofcomposite panels22. Thecomposite panels22 may be coupled to each other using a number of different fasteners and/or joint configurations. Illustratively, thecomposite panels22 are coupled to each other viajoint configurations24 including a logistics plate (not shown) and asplicing plate28. Such joint configurations are described in greater detail in U.S. Pat. No. 7,069,702, the entirety of which is hereby incorporated by reference herein. Of course, it should be understood that other joint configurations and other fasteners (including rivets, screws, bolts, nails, welding, adhesives, and the like) may be used to couple adjacentcomposite panels22 together as well.
• Illustratively, eachcomposite panel22 is generally rectangular having a height greater than its width. Thecomposite panels22 may be relatively equal in size, or, alternatively, the width and/or thickness of eachcomposite panel22 may vary. When thecomposite panels22 are used in the construction of thesidewalls16 and thefront wall assembly18, eachcomposite panel22 is connected to the floor assembly and extends upwardly therefrom such that eachpanel22 is attached to upper andlower rails27,29 of thetrailer10 by suitable joining members, such as bolts or rivets, for example. When thecomposite panels22 are used in the construction of the rear doors, the outer composite panels are connected to therespective sidewalls16 of thetrailer10 by hinges. When closed, the doors extend upwardly from the floor assembly. Although thetrailer10 includes a plurality ofcomposite panels22 coupled to each other to form asingle sidewall16, it is within the scope of this disclosure to provide a trailer having a front end wall and/or sidewalls which are formed from one continuous composite panel.
• Looking now toFIG. 2, eachcomposite panel22 includes ainner metal sheet30, anouter metal sheet32, and a foamed thermalplastic core member34 positioned between the inner andouter sheets30,32. Illustratively, as is described in greater detail below, the inner andouter metal sheets30,32 are bonded to thecore member34, by a thin adhesive layer (not shown). In particular, thesheets30,32, are bonded to the foamed thermalplastic core member34 by a suitable flexible adhesive bonding film such as, for example, modified polyethylene. Of course, it should be understood that any suitable adhesive may be used as well. When fully assembled, theouter sheets32 of each panel20 cooperate to form an outer surface of thesidewalls16 of thetrailer10 while theinner sheets30 of each panel20 cooperate to form an inner surface of thesidewalls16 of thetrailer10.
• Themetal sheets30,32 of each composite panel20 of the present disclosure may be formed of aluminum or full hard, high strength, high tension, galvanized steel. However, other metals or metal alloys may be used as well. Illustratively, eachsheet30,32 has a thickness of greater than nineteen thousandths of an inch. However,sheets30,32 having lesser thicknesses may be used as well.
• Thecore member34 is formed from a foamed thermal plastic, preferably foamed high density polyethylene (HDPE) or high density polyproplylene. Core weight reduction is often achieved by the addition of a gas during the extrusion process in order to produce a foamed thermal plastic, such as thecore member34. This gas, which is typically carbon dioxide, can be physically injected or liberated from chemical additives, creates a foamed core. As such, thecore member34 includes a plurality of air bubbles interspersed with the thermal plastic material. This foaming of thecore member34 lowers the density of the thermal plastic and improves the strength to weight ratio thereof. The foaming of thecore member34 also reduces the weight of thecomposite panel22 as compared to a composite panel having a solid, non-foamed core member. Further, the foamedcore member34 uses less plastic resin versus a solid core member. However, the extent to which the density and the weight reduction may be achieved using this method may be limited by physical process dynamics and needs to maintain acceptable core surface cosmetic appearance and surface area available for effective bonding of the metal sheets to the core.
• While theillustrative core member34 is formed from a foamed HDPE, thecore member34 may alternatively be made from foamed low density thermal plastic, such as foamed low density polyethylene or low density polypropylene. Low density thermal plastic will foam and produce a resilient core member as well. Further, it is within the scope of this disclosure for thecore member34 to be formed from a non-foamed high or low density thermal plastic as well.
• Thecore member34 is generally resilient and is able to flex a certain degree without breaking. Illustratively, thecore member34 is approximately one half of an inch thick or less. However, thecore member34 may be made to define any suitable or desired thickness.
• In order to further reduce the density-to-weight ratio beyond that which is achieved by the foaming process (discussed in greater detail below), holes, orapertures40, are formed into thecore member34, as shown inFIG. 3. Theseapertures40 each penetrate the full thickness of thecore member34. In other words, eachhole40 extends from anouter surface42 of thecore member34 to aninner surface44 of the foamedcore member34. Illustratively, as shown inFIGS. 3 and 4, thecore member34 includes a plurality ofapertures40 which are generally evenly spaced throughout thecore member34. Further illustratively, the plurality ofapertures40 are arranged in alternating rows ofapertures40 to create an array of apertures of thecore member34. Further illustratively, eachaperture40 is circular in shape and has a diameter in the range of approximately ¼ inch to ½ inch.
• Illustratively, theapertures40 shown inFIG. 4 do not open into either the top, bottom or side edges50,52,54 of thecore member34. In other words, the top, bottom, and side edges50,52,54 of the core member are generally solid in that no formed or manufactured apertures are located therein. Specifically, no apertures are formed in theouter edges50,52,54 of thefoam core member34 by a punch or a different type of tool during the manufacturing process. As such, the inner andouter sheets30,32 of thecomposite panel22 are continuously coupled to the respective inner andouter surfaces42,44 of thecore member34 along the top, bottom, and side edges50,52,54 thereof. However, it should be understood that thecore member34 may includeapertures40 which are located at, or open up into, one or more of the top, bottom, and/or side edges50,52,54 of thecore member34.
• It should be understood that while the particular pattern ofapertures40 of theillustrative core member34 is shown inFIGS. 3 and 4,apertures40 may be arranged in any suitable pattern on thecore member34. Further, theapertures40 may be located on only one side (e.g., right, left, top, or bottom) or on only a portion of thecore member34. In other words, theapertures40 need not be positioned to cover generally the entire surface area of thecore member34 from the top of thecore member34 to bottom of thecore member34 and from one side of thecore member34 to the other side of thecore member34. For example, while generally theentire core member34 is perforated to include theapertures40 positioned throughout, it should be understood that the apertures may be positioned in other suitable configurations that do not span the width and/or height of thecore member34. However, generally none of theapertures40 disclosed herein includes a length or a width which is equal to the respective length and width of thecore member34. In other words, none of the core members disclosed herein include a void which extend from one of the top, bottom and/or side edges of thecore member34 to any other of the top, bottom, or side edges of thecore member34. Accordingly, a length and a width (or a diameter, for those apertures which are circular in shape) of eachaperture40 is fess than a respective length and width of thecore member34 in which it is formed. In particular, analternative core member534 is shown inFIG. 11 and includes a pattern ofapertures40 that are spaced-apart from the top, bottom, and side edges50,52,54 of thecore member534. Specifically, a top-most,horizontal row536 ofapertures40 is spaced-apart adistance538 from thetop edge50 of thecore member534. Further, a left-most,vertical row540 of apertures40 (as viewed from above, as shown inFIG. 11) is spaced-apart adistance542 from theleft side edge54 of thecore member534. Illustratively, a bottom-most, horizontal row (not shown) ofapertures40 of thecore member534 is also spaced-apart from the bottom edge (not shown) of thecore member534 while a right-most, vertical row (not shown) ofapertures40 of thecore member534 is also spaced-apart from the right-most edge (not shown) of thecore member534.
• Illustratively, thedistances538 and542 may be equal to each other or may be different from each other. Further illustratively, thecore member534, or any core member disclosed herein, may include any combination of top-most, left and right side-most, and bottom-most rows ofapertures40 which are spaced any other suitable distance away from theedges50,52,54 of thecore member534. In particular, such apertures may be spaced away from theedges50,52,54 in order to provide a suitable space for a fastener to be received through an aperture-free area orportion550,552 of thecore member534. In other words, the distances may be greater than or less than that which is shown inFIG. 11. Further, thecore member534 may include any combination of top-most, left and right side-most, and bottom-most rows of apertures which are not spaced a suitable distance apart from the respective top, side, andbottom edges50,52.54 of thecore member534 in order to be able to receive a fastener through an aperture-free portion of thecore member534.
• Illustratively, adiameter554 of eachaperture40 is approximately 0.250 inches. However, an aperture of any suitable size may be provided within thecomposite member534. Further, a distance558 between a centerpoint of adjacent, vertical rows ofapertures40 is approximately 0.625 inch. Similarly, a distance556 between a centerpoint of adjacent horizontal rows ofapertures40 is also approximately 0.625 inch. However, any suitable distance may be provided between apertures of adjacent horizontal rows or adjacent vertical rows. Further illustratively, adistance560 between theleft edge54 of thecore member534 and the center of theleft-most row540 ofapertures40 of thecore member534 may be approximately 0.50-6.00 inches while adistance562 between theupper edge50 of thecore member534 and the center ofupper-most row536 ofapertures40 of thecore member534 may also be approximately 0.50-6.00 inches. Preferably, thedistance560 of thecore member534 is approximately 6.00 inches while thedistance562 of thecore member534 is approximately 2.00 inches. Illustratively, it should be understood that thecore member534 is illustrative in nature and that other core members having apertures of different shapes and sizes may be provided. Further, core members having different distances between vertical and/or horizontal rows of apertures may be provided and core members having different distances between outer edges and the apertures may be provided as well. Finally, it need not be required that such distances are consistent throughout a single core member.
• Illustratively, the spaced-apartrows536,540 ofapertures40 from the respective top andsides50,54 of thecore member534 provide atop portion550 and aside portion552 of thecore member534 that is free from, or that does not include, anyapertures40. Thetop portion550 of thecore member534 is positioned between thetop edge50 of thecore member534 and the top-most,horizontal row536 ofapertures40 of thecore member534. Theside portion552 of thecore member534 is positioned between the left-most,side edge54 of thecore member534 and the left-most,vertical row540 of theapertures40 of thecore member534.
• As discussed above, thetop portion550 and theside portion552 of thecore member534 provide areas free fromapertures40 that may be used to secure fasteners therethrough in order to couple onecore member534 to anothercore member534 and/or to couple thecore member534 to another object. In particular, rivets, for example, may be punched through the aperture-free portions550,552 of thecore member534 in order to couple thecore member534, or the entire composite panel to which thecore member534 belongs, to another object, including, but not limited toadjacent core members534 and/or adjacent composite panels. Further, fasteners, may also be punched through the aperture-free top and bottom portions of the composite panels to which thecore member534 belongs in order to couple top and bottom rails (not shown) of a trailer to the composite panels. In particular, after the composite panel is formed and the inner andouter sheets30,32 are attached to thecore member534 including theapertures40 and the aperture-free portions550,552, rivet-receiving holes may be punched through the formed composite panel (i.e., theinner sheet30, the aperture-free portions550,552 of thecore member534, and the outer sheet32) such that rivets may then be received through such rivet-receiving holes.
• Looking toFIG. 12, for example, a portion of asidewall551 of a trailer includes a firstcomposite panel522 having thecore member534, and aninner metal sheet30 and anouter metal sheet32 each coupled to thecore member534 via the use of an adhesive. Illustratively, thesidewall551 includes a secondcomposite panel524 similarly having thecore member534, and aninner metal sheet30 and anouter metal32 each coupled to thecore member534 via the use of an adhesive. The first and secondcomposite panels522,524 are adjacent to and spaced-apart from each other in a side-by-side manner. A wall panel joint560 including alogistics member562 and asplicing member564 is provided to couple the adjacentcomposite panels522,524 together. Illustratively, therivets570 used to couple the wall panel joint560 to thecomposite panels522,524 are positioned within the side, aperture-free portion552 of eachcore member534 of thepanels522,524. The same and/or similar wall panel joint is discussed in greater detail in U.S. Pat. No. 6,220,651, the entirety of which is hereby incorporated by reference herein. Illustratively, the wall panel joints discussed in the '651 patent may be used to join together one or more adjacent composite panels disclosed herein.
• While thecomposite panels522,524 ofFIG. 12 are joined together by the wall panel joint560 in order to form at least a portion of a sidewall of a trailer, it should be understood that other wall panel may be used as well. For example, as shown inFIG. 13, a portion of analternative sidewall581 includes a firstcomposite panel582 and a secondcomposite panel584 each including thecore member534, aninner metal sheet30, and anouter metal sheet32. Thecomposite panels582,584 are joined together by a joint590. In particular, the joint590 is a shiplap joint. As shown inFIG. 13, eachcomposite panel582,584 includes an overlappingskin member592 for overlapping a portion of one of therespective metal sheets30,32. Preferably, this overlappingskin member592 is integrally formed as part of therespective metal sheet30,32 of eachcomposite panel582,584. However, it is envisioned that the overlappingskin member590 may be a separate member attached to thecomposite panels582,584 by suitable means. Illustratively, the overlappingskin member590 of eachpanel582,584 is provided for overlapping a portion of the respective inner andouter sheets30,32 of the other,adjacent panel582,584. As shown inFIG. 13, a side end portion of therespective sheets30,32 of thepanels582,584 are coined or stepped by suitable means so as to form a stepped end portion. Because the stepped end portion has been stepped a distance which is equal to the thickness of the overlappingskin member590, the surface formed by theadjacent panels582,584 is substantially flush. This prevents the overlappingskin members592 from being snagged by an outside object. Aconventional rivet member594 is then engaged through aligned rivet-receiving holes provided through the overlappingskin member592 of the firstcomposite panel582 and the stepped end portion of the secondcomposite panel584. A secondconventional rivet member595 is engaged through aligned rivet-receiving holes provided through the stepped end portion of the firstcomposite panel582 and the overlappingskin member592 of the secondcomposite panel584. Illustratively, therivets594,595 used to couple thecomposite panels582,584 together are positioned within the side, aperture-free portion552 of eachcore member534 of thepanels582,584. In other words, the stepped end portions of the first and secondcomposite panels582,584 include the aperture-free portions552 of thecore member534. The same and/or similar wall panel joint is discussed in greater detail in U.S. Pat. No. 5,938,274, the entirety of which is hereby incorporated by reference herein. Illustratively, the wall panel joints discussed in the '274 patent may be used to join together one or more adjacent composite panels disclosed herein.
• It should be understood that the aperture-free portions550,552 of thefoam core534 of the composite panels disclosed herein are free of apertures prior to the process of being joined to adjacent composite panels. The aperture-free portions550,552 provide suitable aperture-free areas or portions of the composite panels for having a rivet-receiving hole formed therethrough. In other words, theapertures40 are non-rivet or non-fastener-receiving apertures that are different from the rivet-receiving holes formed through the already-formed composite panels. These rivet-receiving holes are formed through the entire thickness of the composite panels including the inner andouter sheets30,32 and are not only formed through the foam core contrary to theapertures40 disclosed herein which are formed only through the foam core of a composite panel. In other words, the aperture-free portions define an area of the foam core of a composite panel which does not include any apertures that are formed only through the foam core of the composite panel. Accordingly, the aperture-free portions may later have rivet-receiving holes formed therein. Thus, aperture-free portions550,552 of the composite panel may include rivet-receiving holes which may later be formed through the composite panel in order to join two adjacent composite panels together.
• Illustratively, the pattern of theapertures40 of thecore member534 is different than the pattern of theapertures40 of thecore member34 shown inFIGS. 3 and4. In particular, the pattern of theapertures534 of thecore member534 includes vertical and horizontal rows ofapertures40 that are all aligned with each other. In other words, every vertical row ofapertures40 of thecore member534 is aligned with every adjacent vertical row ofapertures40 of thecore member534. Further, every horizontal row ofapertures40 of thecore member534 is aligned with every adjacent horizontal row ofapertures40 of thecore member534. However, the pattern of theapertures40 of thecore member34 includes staggered, or offset, vertical and horizontal rows ofapertures40, as shown inFIG. 4, such that every other vertical row ofapertures40 of thecore member34 is aligned with every other (and not every adjacent) vertical row ofapertures40 of thecore member34 and every horizontal row ofapertures40 of thecore member34 is aligned with every other (and not every adjacent) horizontal row ofapertures40 of thecore member34. Illustratively, while the specific patterns ofapertures40 are shown in thecore member34 and thecore member534, it should be understood that a core member may be provided which includes any suitable pattern of apertures formed therethrough including any number of aligned and/or misaligned horizontal and vertical rows of apertures. Further, a random array of apertures having not particular pattern may be provided as well.
• While theparticular apertures40 of each of thecore members34,534 are circular in shape, it should be understood that themembers34,534 may includeapertures40 of any shape, such as square, rectangular, triangular, oval, etc. Further, it should be understood that thecore members34,534 may each include apertures of any suitable size having any suitable dimensions. Finally, while thecore members34,534 each include an array ofapertures40 which are all of the same shape and size, it should be understood that thecore members34,534 may include apertures of varying dimension, size, and/or shape. In other words, while theapertures40 of theillustrative core members34,534 are all of uniform shape and size, thecore members34,534 may each include any number of apertures having different sizes and/or shapes. In other words, the spacing, dimension, and geometry of the apertures of thecore members34,534 may be different and optimized according to specific production process and performance specifications. Finally, while theapertures40 of each of thecore members34,534 are shown to be spaced a particular distance apart from each other that is generally uniform, it should be understood that thecore members34,534 may each include apertures which are spaced further or closer apart than that which is shown and may also include apertures which are spaced a non-uniform distance from adjacent apertures.
• Looking toFIG. 5, for example, analternative core member134 is similar to thecore members34,534. As such, like reference numerals are used to denote like components. Rather than the circular-shapedapertures40 of thecore members34,534, thecore member134 includes a plurality of generally diamond-shapedapertures140. Illustratively, the diamond-shapedapertures140 are approximately % inch to ⅜ inch wide and ½ inch to ¾ inch tall. However, theapertures140 may have any suitable height and/or width. As discussed above in regard to theapertures40, theapertures140 extend through the entire thickness of thecore member134 from theoutside surface42 to theinside surface44 of thecore member134.
• Looking now toFIG. 6, an illustrative process ormethod150 for making thecomposite panel22 is schematically illustrated. Illustratively, a foamedcore sheet80 is first made by mixing foaming beads orpellets82 with thermal plastic resin beads orpellets84. Thesepellets82,84 are mixed in a mixingchamber86 using an auger (not shown). The foamingpellets82 have a gas therein, such as carbon dioxide or nitrogen, for example. Themixed pellets82,84 are subjected to heat in ahot die chamber88 and the foamingpellets82 activate and produce carbon dioxide or nitrogen to foam the mixture. The mixture is then extruded into a layer by anextruder90 to form the foamedcore80. Illustratively, the foamedcore sheet80 is approximately 350° F. upon leaving theextruder90. It should be understood that other methods of foaming the core member may be provided such as by injecting nitrogen into a heating chamber in which the thermal plastic resin pellets are being heated and are in a molten state (without the use of the foaming pellets being mixed therewith) and thereafter extruding the foamed core material onto a core member, or by using both the foaming pellets and the direct injection of nitrogen gas into a heating chamber in which both the thermal plastic resin pellets and the foaming pellets are being heated. Making a foamed core, such as the foamedcore80, is described in greater detail in U.S. Application Publication No. 2001/0011832, the entirety of which is hereby incorporated by reference herein. As noted above, while themethod150 of making thecomposite panel22 includes making the foamedcore sheet80, it should be understood that thecomposite panel22 may include a non-foamed core sheet as well.
• Once the foamedcore sheet80 is formed, a first set ofrollers92 advances the foamedcore80 to arotary die cutter94 including anupper roller punch96 and alower roller98. Illustratively, therollers92 are chilled rollers in order to cool the hot, extruded foamedcore sheet80. Further illustratively, the upper die roller punch96 maybe an engraved steel cylinder on a roll-fed press. As shown inFIG. 6, theupper die roller96 includes roller mounted hollow punches, or protrusions,100 having a circular cross-section. Theseprotrusions100 operate to pierce the foamedcore sheet80 as it is advanced between theupper die roller94 and thelower roller96, The punches, orprotrusions100, react against thebottom roller98 on the opposite side of the foamedcore sheet80. Theprotrusions100 illustratively form theapertures40 into the foamedcore sheet80 in order to produce thecore member34.
• During the die cutting process, slugs of material102 displaced from thecore sheet80 are produced. Illustratively, such slugs of material102 may be extracted from thebottom roller98, recycled, and reused to make additional core sheets or other devices including foamed components as well.
• Once thecore member34, including theapertures40, is formed, thecore member34 is advanced through a set of upper and lowerheated laminating rollers104,106 where the inner andouter sheets30,32 are laminated to each respective inner andouter surface42,44 of thecore member34. Illustratively, a layer of flexible adhesive (not shown) may be applied to the inner surface of each of thesheets30,32 prior to laminating thesheets30,32 to thecore member34. Alternatively, the layer of flexible adhesive may be applied directly to theopposite surfaces42,44 of thecore member34. Further alternatively, theopposite surfaces42,44 of thecore member34 may be treated with a spray adhesive to create an adhesive bonding layer on theopposite surfaces42,44 such that themetal sheets30,32 may be directly bonded thereto. Regardless of the type of adhesive used or the method by which the adhesive is applied, the inner andouter metal sheets30,32 are adhered to thecore member34 by the adhesive layer under pressure in order to create thecomposite panel22. Illustratively, after being formed,composite panel22 may be cut to any suitable length.
• Looking now toFIG. 7, an alternative process ormethod250 for making thecomposite panel22 is schematically illustrated. Illustratively, much of the process includes the same or similar steps; as such, like reference numerals are used to denote like components. In particular, the foamedcore sheet80 is produced in the same manner as that described above in regard toFIG. 6. Once the foamedcore sheet80 is formed, the first set ofrollers92 advances the foamedcore sheet80 to a cam-actuatedroller punch cutter194 which similarly operates to pierce thecore sheet80 in order to form theapertures40 therethrough. Illustratively, the cam-actuatedroller punch cutter194 includes anupper roller196 and alower roller198 against which theupper roller punch196 reacts during the punch cutting process. Theupper roller196 includes acam member199 having cam-actuatedhollow punches200 coupled thereto. In use, the cam-actuatedhollow punches200 are forced out through punch holes202 formed in theroller punch196 as theroller punch196 is pivoted about its central axis. Further illustratively, thelower roller198 includes die buttons orapertures204 through which the core slugs108 may pass for removal from the process and subsequent recycling. Once thecore member34 is formed through the use of the cam-actuatedroller punch cutter194, thecomposite panel22 is formed in the same or similar manner as that described above with reference toFIG. 6.
• In yet another method for producing thecore member34, a bank of vertical punches and underlying die buttons (not shown) may by used. Such punches and die buttons may travel in a synchronized linear motion with the foamedcore sheet80 while making the through-cuts in the foamedsheet80 to form theapertures40. The punches may make vertical penetration strokes to form the through-cuts, and after withdrawing from the penetration stroke, the bank of punches may return to a start position and again synchronize with the movingcore sheet80 for the next penetration sequence. As shown inFIG. 10, for example, amethod650 for producing thecore member534 is provided. Illustratively, the foamedcore sheet80 is produced in the same manner as that described above in regards toFIGS. 6 and 7. Once the foamedcore sheet80 is formed, the first set ofrollers92 advances the foamedcore sheet80 to atransversing punch696. As noted above, the first set ofrollers92 operate to cool the foamedcore sheet80 as it leaves theextruder90 and is moved toward thepunch696. Illustratively, while onlylower rollers92 are shown inFIG. 10, it should be understood thatupper rollers92 may be provided as well. Further, it should be understood that while only a single upper andlower roller92 is shown inFIGS. 6 and 7, a plurality of lower and/orupper rollers92 may be provided in order to advance and cool the foamedcore sheet80 from theextruder90 to thetransversing punch cutter696.
• Once the foamedcore sheet80 is advanced to thetransversing punch696, the transversingpunch696 similarly operates to pierce thecore sheet80 in order to form theapertures40 therethrough. Illustratively, the transversingpunch696 includes anupper platform698 including thevertical punches700 extending downwardly therefrom. The transversingpunch696 illustratively extends across a height of the foamedcore sheet80 from atop edge50 of the sheet to abottom edge52 of the sheet. The transversingpunch696 further includes alower platform702 coupled to theupper platform698 for back and forth movement (shown by arrow652) therewith. Illustratively, the transversingpunch696 rests on a table704 for back and forth movement across the width of the table704.
• As noted above, the foamedcore sheet80 is approximately 350° F. upon leaving theextruder90 and is illustratively cooled by thechilled rollers92 to approximately 250° F. when thetransversing punch696 forms theapertures40 therein. As this hot foamedcore sheet80 advances toward thepunch696, thepunch696 moves back and forth along the table704 while thevertical punches700 operate to pierce thecore sheet80 to form theapertures40 therethrough. The core slugs (not shown) produced from piercing thecore sheet80 may fall below and be removed from the process for subsequent recycling. Once thecore member534 is formed through the use of thetransversing punch696, the composite panel522 (shown inFIG. 12) is formed in the same or similar manner as that described above with reference toFIGS. 6 and 7.
• Illustratively, and similar to that discussed above inFIGS. 6 and 7, thecomposite panels22,522 including therespective core members34,534 are produced continuously in a line using a “hot” foamedcore sheet80 of approximately 250° F. Theapertures40 are formed in the foamedcore sheet80 while the foamedcore sheet80 is still “hot.” Illustratively, it should be understood that the term “hot” should not be limited to a temperature of approximately 250° F., but rather should refer simply to a foamedcore sheet80 that remains rather pliable and flexible and that has not cooled to a state where it is not flexible or pliable and/or has not cooled to room temperature. It should also be understood that the heat from the hot foamedcore sheet80 may affect the tolerances of the equipment used to the punch theapertures40 in thesheet80. As such, the equipment, such as the dies94,194 and thepunch696 may need to be cooled as they are operating to pierce theapertures40 in the foamedcore sheet80.
• Looking now toFIG. 8, amethod350 for making acomposite panel322 including thecore member134 shown inFIG. 5 is schematically illustrated. Illustratively, much of the process includes the same or similar steps as that described above with reference toFIGS. 6 and 7; as such, like reference numerals are used to denote like components. In particular, the foamedcore sheet80 is produced in the same manner as that described above in regards toFIGS. 6 and 7. Once the foamedcore sheet80 is formed, the first set ofrollers92 advances the foamedcore sheet80 to arotary die cutter294 including anupper die roller296 and alower roller298. As shown inFIG. 8, theupper die roller296 includes roller mountedprotrusions300 in the shape of knife-like blades. Illustratively, theblades300 are thin and slender and operate to pierce the extruded foamedcore sheet80 in a predetermined pattern as the foamedcore sheet80 is advanced between theupper die roller296 and thelower roller298. Theblades300 react against thebottom roller298 to createslots302 within the foamedcore80.
• Looking still toFIG. 8, the roller mountedblades300 operate to pierce thecore sheet80 in a regular pattern. Illustratively, theslots302 formed in the foamedcore sheet80 define a longitudinal axis that is parallel to the longitudinal axis of the foamedcore sheet80. In other words, the length of theslots302 extends along the length of the foamedcore sheet80 such that theslots302 are also parallel to the upper andlower edges81,83 of the foamedcore sheet80. As is discussed below, while theillustrative slots302 extend along a length of the foamedcore sheet30, it is within the scope of thisdisclosure form slots302 which are not parallel to the length, or longitudinal axis, of the foamedcore sheet80 and which are, therefore, angled relative to the longitudinal axis of the foamedcore sheet80.
• As opposed to theprocesses150,250 described above (and shown schematically inFIGS. 6 and 7), thedie cutting process350 ofFIG. 8 does not create or displace any slugs of material from thecore sheet80. As such, illustratively, no such slugs of material need be extracted from thebottom roller298 for subsequent recycling or reuse.
• Once theslots302 are formed in thecore sheet80, the now-slottedcore sheet80 is then subjected towidth-wise forces310 to expand thecore sheet80 and theslots302 formed therein to create the generally diamond-shapedslots140 of thecore member134. The expandingforce310 is applied at right angles to the core process flow thereby creating theapertures140 that are generally diamond-shaped. In particular, as shown schematically inFIG. 8, thewidth-wise forces310 operated to exert an outward force on the slottedcore sheet80 in outward directions perpendicular to the longitudinal axis of the foamedcore sheet80. Suchoutward force310 operates to increase the width of the slottedfoamed core sheet80 while also pulling apart theopposite edges141,143 defining eachslot302 in order to form the generally diamond-shapedslots140. This geometry and increased core width is illustratively retained as thecore member134 is cooled. Illustratively, one or both core sheet edges81,83 may be left clear of proximate perforations thereby leaving a continuous material strip for subsequent joining by the use of mechanical or other fastening systems. Once thecore member134 is formed through the use of thedie cutter294, thecomposite panel322 is formed in the same or similar manner as that described above with reference toFIGS. 6 and 7.
• Alternatively, it should be understood that rather than passing the foamedcore sheet80 through therotary die cutter294, as described above and shown inFIG. 8, theprotrusions300 may be mounted to a bank of punches (not shown) which are actuated in a vertical motion in synchronism with the movingcore sheet80 in order to create theslots302 in thesheet80.
• Looking now toFIG. 9, amethod450 for making anothercomposite panel422 including analternative core member234 is schematically illustrated. Illustratively, much of theprocess450 includes the same or similar steps as that described above with reference toFIGS. 6-8; as such, like reference numerals are used to denote like components. In particular, the foamedcore sheet80 is produced in the same manner as that described above in regards toFIGS. 6-8. Once the foamedcore sheet80 is formed, the first set ofrollers92 advances the foamedcore sheet80 to arotary die cutter394 including anupper die roller396 and alower roller398. As shown inFIG. 9, theupper die roller396 includes roller mountedprotrusions400 in the shape of knife-like blades. Illustratively, as opposed to theprotrusions300 of theupper die roller296 shown inFIG. 8, a longitudinal axis of theprotrusions400 is parallel to the longitudinal axis of theupper die roller396 itself. Illustratively, theblades400 are similarly thin and slender and operate to pierce the extruded foamedcore sheet80 in a predetermined pattern as the foamedcore sheet80 is advanced between theupper die roller396 and thelower roller398. Theblades400 react against thebottom roller398 to createslots402 within the foamedcore80.
• Illustratively, the roller mountedblades400 pierce thecore sheet80 in a regular pattern to produceslots402 at right angles to the core edges81,83. In particular, theillustrative slots402 formed in the foamedcore sheet80 define a longitudinal axis that is perpendicular to the longitudinal axis of the foamedcore sheet80. In other words, the length of theslots402 extends perpendicularly to the length of the foamedcore sheet80 such that theslots402 are also perpendicular to the upper andlower edges81,83 of the foamedcore sheet80. Similar to thedie cutting process350 ofFIG. 8, little or no slugs of material are created or displaced from thecore sheet80 when theslots402 are formed.
• Once theslots402 are formed in the foamedcore sheet80, the now-slottedcore sheet80 is then passed through upper and lower pull-rollers406,408. The pull-rollers406,408 operate to subject the slottedcore sheet80 to length-wise, or tensile,forces410 in the direction of travel to expand thecore sheet80 and theslots402 formed therein. Subjecting theslots402 to these tensile forces expands theslots402 to create generally diamond-shaped slots orapertures240 of thecore member234. As shown schematically inFIG. 9, thelength-wise forces410 operate to exert a force on the slottedcore sheet80 along the length of thesheet80 to increase the length of the slottedfoamed sheet80 while also pulling apart theopposite edges141,143 defining eachslot402 in order to form the generally diamond-shapedslots240. Illustratively, as opposed to the diamond-shapedslots140 of thecore member134 shown inFIGS. 5 and 8, a length of the diamond-shapedslots240 of thecore member234 is perpendicular to the length of thecore member134. Once thecore member234 is formed through the use of thedie cutter394, thecomposite panel422 is formed in the same or similar manner as that described above with reference toFIGS. 6-8.
• Again, alternatively, it should be understood that rather than passing the foamedcore sheet80 through therotary die cutter394, as described above and shown inFIG. 9, theprotrusions400 may be mounted to a bank of punches (not shown) which are actuated in a vertical motion in synchronism with the movingcore sheet80 in order to create theslots402 in thesheet80.
• While the invention has been illustrated and described in detail in the foregoing drawings and description, the same is to be considered as illustrative and not restrictive in character, it being understood that only illustrative embodiments thereof have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. In particular, a foamed core member, such as the foamedcore members34,134,534, includesapertures40,140 formed through a thickness (i.e., from theouter surface42 to the inner surface44) of the core member. The apertures of such a foamed core member of the present disclosure may be any suitable shape and size. The apertures may be spaced any suitable distance apart from each other and may be arranged in any suitable pattern and/or may be arranged randomly. Illustratively, the apertures are not interconnected and no single aperture extends between a top edge and a bottom edge of any core member to create a continuous void from the top edge to the bottom edge. Further, no single aperture extends between the side edges of any core member to create a continuous void from the side edges of the core member. The apertures of a core member of the present disclosure may be open to the top, bottom, and side edges50,52,54. Alternatively, the apertures of a core member of the present disclosure may be spaced-apart from the top, bottom, and side edges50,52,54 such that the top, bottom, and side edges of the core member are generally continuous and do not include any formed, or manufactured, voids formed therein. The apertures may be spaced-apart any suitable distance from theedges50,52,54 of the core member. In particular, a distance that is perpendicular from anyedge50,52,54 and the center of any adjacent aperture may illustratively be in the range of approximately 0.50 inch-6.00 inches. However, it should be understood that such a distance between the apertures and the edges may be greater than or less than the above-referenced range.

Claims (20)

What is claimed is:

1. A composite panel configured for use with a sidewall of a trailer comprising:

an outer metal sheet;

an inner metal sheet; and

a core member positioned between the inner and outer metal sheets, wherein the core member includes a plurality of apertures formed therethrough such that each aperture extends from an inner surface of the core member to an outer surface of the core member, wherein the plurality of apertures is covered by the inner and outer metal sheets, and wherein a length and width of each aperture is less than a respective length and width of the core member.

2. The composite panel ofclaim 1, wherein the plurality of apertures are circular in shape.

3. The composite panel ofclaim 2, wherein a diameter of each aperture is in the range of approximately ¼ inch to ½ inch.

4. The composite panel ofclaim 1, further comprising an adhesive between the inner metal sheet and the core member and between the outer metal sheet and the core member.

5. The composite panel ofclaim 1, wherein the plurality of apertures includes a plurality of adjacent vertical rows of apertures that are aligned with each other and a plurality of adjacent horizontal rows of apertures that are aligned with each other.

6. The composite panel ofclaim 1, wherein the plurality of apertures includes a plurality of adjacent vertical rows of apertures that are offset from each other and a plurality of adjacent horizontal rows of apertures that are offset from each other.

7. The composite panel ofclaim 1, wherein a top-most horizontal row of apertures is spaced-apart from a top edge of the core member.

8. The composite panel ofclaim 7, wherein a vertical distance between the top edge of the core member and a center of the top-most horizontal row of apertures is between approximately 0.50-6.00 inches.

9. The composite panel ofclaim 8, wherein the vertical distance is approximately 2.0 inches.

10. The composite panel ofclaim 1, wherein a left-most vertical row of apertures is spaced-apart from a left side edge of the core member.

11. The composite panel ofclaim 10, wherein a horizontal distance between the left side edge of the core member and a center of the left-most vertical row of apertures is between approximately 0.50-6.00 inches.

12. The composite panel ofclaim 11, wherein the horizontal distance is approximately 6.0 inches.

13. The composite panel ofclaim 1, wherein a top-most horizontal row of apertures is spaced-apart a first distance from a top edge of the core member, wherein a left-most vertical row of apertures is spaced-apart a second distance from a left side edge of the core member, and wherein the first distance is smaller than the second distance.

14. The composite panel ofclaim 1, wherein the apertures are generally uniformly spaced-apart from one another.

15. The composite panel ofclaim 1, wherein the apertures are generally similarly-sized.

16. The composite panel ofclaim 1, wherein the core member is a foamed core member including a plurality of air bubbles therein.

17. The composite panel ofclaim 1, wherein none of the plurality of apertures is open to any one of a top, bottom, or side edge of the core member.

18. The composite panel ofclaim 1, wherein the plurality of apertures includes a plurality of vertically-spaced apart apertures and a plurality of horizontally spaced-apart apertures.

19. A sidewall of a trailer comprising

a first composite panel including (i) a first outer metal sheet, (ii) a first inner metal sheet, and (iii) a first core member positioned between the first inner and first outer metal sheets, wherein the first core member includes a first plurality of apertures which are both vertically and horizontally spaced-apart from each other, wherein each of the first plurality of apertures extends from an inner surface of the first core member to an outer surface of the first core member, wherein the first plurality of apertures is covered by the first inner and first outer metal sheets, wherein the first core member includes a first aperture-free side portion;

a second composite panel including (i) a second outer metal sheet, (ii) a second inner metal sheet, and (iii) a second core member positioned between the second inner and second outer metal sheets, wherein the second core member includes a second plurality of apertures which are both vertically and horizontally spaced-apart from each other, wherein each of the second plurality of apertures extends from an inner surface of the second core member to an outer surface of the second core member, wherein the second plurality of apertures is covered by the second inner and second outer metal sheets, wherein the second core member includes a second aperture-free side portion; and

a wall joint coupling the first and second composite panels to each other, the wall joint including a plurality of fasteners received through the first and second aperture-free portions of the first and second composite panels.

20. A method of forming a composite panel configured for use in a sidewall of a trailer, the method comprising:

forming an uncooled thermal plastic sheet of material;

advancing the uncooled thermal plastic sheet of material through a transversing punch in order to form apertures through the uncooled thermal plastic sheet of material such that each aperture extends from an outer surface of the thermal plastic sheet of material to an inner surface of the thermal plastic sheet of material;

cooling the transversing punch; and

coupling an outer metal sheet and an inner metal sheet to the respective outer surface and the inner surface of the uncooled thermal plastic sheet of material.

Images