Apparatus and method for fabricating structural panels...

B - Operations – Transporting – 32 – B

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154/118, 154/30.

B32B 3/28 (2006.01) B29C 65/00 (2006.01) B29C 65/14 (2006.01) B29D 24/00 (2006.01)

Patent

CA 1333685

An apparatus and method for continuously fabricat- ing lightweight structural panels and the structural panel fabricated thereby are provided, the apparatus being capable of heating a core sheet to a temperature at which the sheet will be plastically deformable such that a corrugation form- ing means comprising a cylindrical forming drum having a plurality of annular recesses and a plurality of forming mandrels will form a plurality of axially extending corruga- tions. The fabricating apparatus is further provided with heaters to heat the surfaces of the core sheet, and one or two skin sheets to be bonded to the core sheet, the core sheet being heated to a process temperature at which the surfaces of the thermoplastic sheet become tacky and exhibit adhesive properties, and contact surfaces of the skin sheet or sheets being heated to a temperature below the core sheet process temperature, whereupon pressure applied between the skin sheets and the corrugated core sheet produces a self- adhesive bond between the sheets and forms a panel. The outer surfaces of the skin sheets are protected by maintain- ing these surfaces at sufficiently cool temperatures to resist distortion. The apparatus and method are especially suitable for use with glass-reinforced thermoplastic-compos- ite sheet stock of indefinite length.

599453

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