U.S. patent application number 13/204762 was filed with the patent office on 2012-02-16 for composite panel having perforated foam core.
Invention is credited to Dwaine D. Speer.
Application Number | 20120040131 13/204762 |
Document ID | / |
Family ID | 45565027 |
Filed Date | 2012-02-16 |
United States Patent
Application |
20120040131 |
Kind Code |
A1 |
Speer; Dwaine D. |
February 16, 2012 |
Composite Panel Having Perforated Foam Core
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.
Inventors: |
Speer; Dwaine D.; (West
Lafayette, IN) |
Family ID: |
45565027 |
Appl. No.: |
13/204762 |
Filed: |
August 8, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61372259 |
Aug 10, 2010 |
|
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Current U.S.
Class: |
428/131 ;
29/428 |
Current CPC
Class: |
B32B 15/04 20130101;
B32B 2250/00 20130101; B32B 15/085 20130101; B32B 15/08 20130101;
B32B 2250/44 20130101; Y10T 29/49826 20150115; B32B 27/32 20130101;
Y10T 428/24273 20150115; B32B 2250/03 20130101; B32B 15/20
20130101; B32B 37/24 20130101; B32B 15/18 20130101; B32B 2250/40
20130101; B32B 5/18 20130101; B32B 2605/08 20130101; B32B 3/266
20130101; B62D 29/002 20130101; B62D 29/005 20130101; B32B 2605/00
20130101 |
Class at
Publication: |
428/131 ;
29/428 |
International
Class: |
B32B 3/10 20060101
B32B003/10; B23P 17/04 20060101 B23P017/04 |
Claims
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 of claim 1, wherein the plurality of
apertures are circular in shape.
3. The composite panel of claim 2, wherein a diameter of each
aperture is in the range of approximately 1/4 inch to 1/2 inch.
4. The composite panel of claim 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 of claim 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 of claim 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 of claim 1, wherein a top-most horizontal
row of apertures is spaced-apart from a top edge of the core
member.
8. The composite panel of claim 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 of claim 8, wherein the vertical distance is
approximately 2.0 inches.
10. The composite panel of claim 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 of claim 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 of claim 11, wherein the horizontal
distance is approximately 6.0 inches.
13. The composite panel of claim 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 of claim 1, wherein the apertures are
generally uniformly spaced-apart from one another.
15. The composite panel of claim 1, wherein the apertures are
generally similarly-sized.
16. The composite panel of claim 1, wherein the core member is a
foamed core member including a plurality of air bubbles
therein.
17. The composite panel of claim 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 of claim 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.
Description
[0001] This application claims priority under 35 U.S.C.
.sctn.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
[0002] 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
[0003] 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.RTM. 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
[0004] 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.
[0005] 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.
[0006] 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 1/4 inch to 1/2
inch.
[0007] 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.
[0008] 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.
[0009] 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.
[0010] 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.
[0011] 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.
[0012] 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.
[0013] In yet another illustrative embodiment, the apertures may be
generally uniformly spaced-apart from one another.
[0014] In still another illustrative embodiment, the apertures may
be generally similarly-sized.
[0015] In yet another illustrative embodiment, the core member may
be a foamed core member including a plurality of air bubbles
therein.
[0016] 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.
[0017] 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.
[0018] 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.
[0019] 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
[0020] FIG. 1 is a perspective view of a trailer having sidewalls
including a plurality of composite panels.
[0021] FIG. 2 is a perspective view of a portion of one of the
composite panels of FIG. 1 showing two outer metal skins and an
inner foam core of the panel.
[0022] FIG. 3 is a perspective, exploded view of the composite
panel of FIG. 2 showing the foam core including a plurality of
holes formed therethrough.
[0023] FIG. 4 is a planar view of the foam core of FIG. 3.
[0024] FIG. 5 is a planar view of an alternative foam core.
[0025] FIG. 6 is a schematic of a first method of making the
composite panel FIG. 2.
[0026] FIG. 7 is a schematic of a second method of making the
composite panel of FIG. 2.
[0027] FIG. 8 is a schematic of a third method of making of a
composite panel having the foam core of FIG. 5.
[0028] FIG. 9 is a schematic of a fourth method of making a
composite panel having an alternative foam core.
[0029] FIG. 10 is a schematic of a fifth method of making a
composite panel having an alternative foam core.
[0030] FIG. 11 is a planar view of an alternative foam core.
[0031] 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 of FIG. 11.
[0032] 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 of FIG. 11.
DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0033] 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.
[0034] Looking first to FIGS. 1-3, a truck trailer 10 includes a
roof assembly 12 coupled to opposite sidewalls 16, a front end wall
assembly 18, 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, the
trailer 10 also includes a floor assembly (not shown) spaced apart
from the roof assembly 12. Further illustratively, the trailer 10
is connected to a tractor 20 by conventional means, such as a fifth
wheel, for example.
[0035] Illustratively, each sidewall 16 and the front end wall 18
of the trailer 10 are made from a plurality of composite panels 22.
The composite panels 22 may be coupled to each other using a number
of different fasteners and/or joint configurations. Illustratively,
the composite panels 22 are coupled to each other via joint
configurations 24 including a logistics plate (not shown) and a
splicing plate 28. 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 adjacent composite panels 22
together as well.
[0036] Illustratively, each composite panel 22 is generally
rectangular having a height greater than its width. The composite
panels 22 may be relatively equal in size, or, alternatively, the
width and/or thickness of each composite panel 22 may vary. When
the composite panels 22 are used in the construction of the
sidewalls 16 and the front wall assembly 18, each composite panel
22 is connected to the floor assembly and extends upwardly
therefrom such that each panel 22 is attached to upper and lower
rails 27, 29 of the trailer 10 by suitable joining members, such as
bolts or rivets, for example. When the composite panels 22 are used
in the construction of the rear doors, the outer composite panels
are connected to the respective sidewalls 16 of the trailer 10 by
hinges. When closed, the doors extend upwardly from the floor
assembly. Although the trailer 10 includes a plurality of composite
panels 22 coupled to each other to form a single sidewall 16, 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.
[0037] Looking now to FIG. 2, each composite panel 22 includes a
inner metal sheet 30, an outer metal sheet 32, and a foamed thermal
plastic core member 34 positioned between the inner and outer
sheets 30, 32. Illustratively, as is described in greater detail
below, the inner and outer metal sheets 30, 32 are bonded to the
core member 34, by a thin adhesive layer (not shown). In
particular, the sheets 30, 32, are bonded to the foamed thermal
plastic core member 34 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, the outer sheets 32 of each panel 20 cooperate to
form an outer surface of the sidewalls 16 of the trailer 10 while
the inner sheets 30 of each panel 20 cooperate to form an inner
surface of the sidewalls 16 of the trailer 10.
[0038] The metal sheets 30, 32 of each composite panel 20 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, each sheet 30, 32
has a thickness of greater than nineteen thousandths of an inch.
However, sheets 30, 32 having lesser thicknesses may be used as
well.
[0039] The core member 34 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 the core member 34. This gas,
which is typically carbon dioxide, can be physically injected or
liberated from chemical additives, creates a foamed core. As such,
the core member 34 includes a plurality of air bubbles interspersed
with the thermal plastic material. This foaming of the core member
34 lowers the density of the thermal plastic and improves the
strength to weight ratio thereof. The foaming of the core member 34
also reduces the weight of the composite panel 22 as compared to a
composite panel having a solid, non-foamed core member. Further,
the foamed core member 34 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.
[0040] While the illustrative core member 34 is formed from a
foamed HDPE, the core member 34 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 the core
member 34 to be formed from a non-foamed high or low density
thermal plastic as well.
[0041] The core member 34 is generally resilient and is able to
flex a certain degree without breaking. Illustratively, the core
member 34 is approximately one half of an inch thick or less.
However, the core member 34 may be made to define any suitable or
desired thickness.
[0042] 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, or apertures 40, are formed into the
core member 34, as shown in FIG. 3. These apertures 40 each
penetrate the full thickness of the core member 34. In other words,
each hole 40 extends from an outer surface 42 of the core member 34
to an inner surface 44 of the foamed core member 34.
Illustratively, as shown in FIGS. 3 and 4, the core member 34
includes a plurality of apertures 40 which are generally evenly
spaced throughout the core member 34. Further illustratively, the
plurality of apertures 40 are arranged in alternating rows of
apertures 40 to create an array of apertures of the core member 34.
Further illustratively, each aperture 40 is circular in shape and
has a diameter in the range of approximately 1/4 inch to 1/2
inch.
[0043] Illustratively, the apertures 40 shown in FIG. 4 do not open
into either the top, bottom or side edges 50, 52, 54 of the core
member 34. In other words, the top, bottom, and side edges 50, 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 the outer edges 50, 52, 54 of the foam core
member 34 by a punch or a different type of tool during the
manufacturing process. As such, the inner and outer sheets 30, 32
of the composite panel 22 are continuously coupled to the
respective inner and outer surfaces 42, 44 of the core member 34
along the top, bottom, and side edges 50, 52, 54 thereof. However,
it should be understood that the core member 34 may include
apertures 40 which are located at, or open up into, one or more of
the top, bottom, and/or side edges 50, 52, 54 of the core member
34.
[0044] It should be understood that while the particular pattern of
apertures 40 of the illustrative core member 34 is shown in FIGS. 3
and 4, apertures 40 may be arranged in any suitable pattern on the
core member 34. Further, the apertures 40 may be located on only
one side (e.g., right, left, top, or bottom) or on only a portion
of the core member 34. In other words, the apertures 40 need not be
positioned to cover generally the entire surface area of the core
member 34 from the top of the core member 34 to bottom of the core
member 34 and from one side of the core member 34 to the other side
of the core member 34. For example, while generally the entire core
member 34 is perforated to include the apertures 40 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 the core member 34. However, generally none
of the apertures 40 disclosed herein includes a length or a width
which is equal to the respective length and width of the core
member 34. 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 the core member 34 to any other of the top,
bottom, or side edges of the core member 34. Accordingly, a length
and a width (or a diameter, for those apertures which are circular
in shape) of each aperture 40 is fess than a respective length and
width of the core member 34 in which it is formed. In particular,
an alternative core member 534 is shown in FIG. 11 and includes a
pattern of apertures 40 that are spaced-apart from the top, bottom,
and side edges 50, 52, 54 of the core member 534. Specifically, a
top-most, horizontal row 536 of apertures 40 is spaced-apart a
distance 538 from the top edge 50 of the core member 534. Further,
a left-most, vertical row 540 of apertures 40 (as viewed from
above, as shown in FIG. 11) is spaced-apart a distance 542 from the
left side edge 54 of the core member 534. Illustratively, a
bottom-most, horizontal row (not shown) of apertures 40 of the core
member 534 is also spaced-apart from the bottom edge (not shown) of
the core member 534 while a right-most, vertical row (not shown) of
apertures 40 of the core member 534 is also spaced-apart from the
right-most edge (not shown) of the core member 534.
[0045] Illustratively, the distances 538 and 542 may be equal to
each other or may be different from each other. Further
illustratively, the core member 534, or any core member disclosed
herein, may include any combination of top-most, left and right
side-most, and bottom-most rows of apertures 40 which are spaced
any other suitable distance away from the edges 50, 52, 54 of the
core member 534. In particular, such apertures may be spaced away
from the edges 50, 52, 54 in order to provide a suitable space for
a fastener to be received through an aperture-free area or portion
550, 552 of the core member 534. In other words, the distances may
be greater than or less than that which is shown in FIG. 11.
Further, the core member 534 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, and bottom edges 50, 52. 54 of the core
member 534 in order to be able to receive a fastener through an
aperture-free portion of the core member 534.
[0046] Illustratively, a diameter 554 of each aperture 40 is
approximately 0.250 inches. However, an aperture of any suitable
size may be provided within the composite member 534. Further, a
distance 558 between a centerpoint of adjacent, vertical rows of
apertures 40 is approximately 0.625 inch. Similarly, a distance 556
between a centerpoint of adjacent horizontal rows of apertures 40
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, a distance 560
between the left edge 54 of the core member 534 and the center of
the left-most row 540 of apertures 40 of the core member 534 may be
approximately 0.50-6.00 inches while a distance 562 between the
upper edge 50 of the core member 534 and the center of upper-most
row 536 of apertures 40 of the core member 534 may also be
approximately 0.50-6.00 inches. Preferably, the distance 560 of the
core member 534 is approximately 6.00 inches while the distance 562
of the core member 534 is approximately 2.00 inches.
Illustratively, it should be understood that the core member 534 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.
[0047] Illustratively, the spaced-apart rows 536, 540 of apertures
40 from the respective top and sides 50, 54 of the core member 534
provide a top portion 550 and a side portion 552 of the core member
534 that is free from, or that does not include, any apertures 40.
The top portion 550 of the core member 534 is positioned between
the top edge 50 of the core member 534 and the top-most, horizontal
row 536 of apertures 40 of the core member 534. The side portion
552 of the core member 534 is positioned between the left-most,
side edge 54 of the core member 534 and the left-most, vertical row
540 of the apertures 40 of the core member 534.
[0048] As discussed above, the top portion 550 and the side portion
552 of the core member 534 provide areas free from apertures 40
that may be used to secure fasteners therethrough in order to
couple one core member 534 to another core member 534 and/or to
couple the core member 534 to another object. In particular,
rivets, for example, may be punched through the aperture-free
portions 550, 552 of the core member 534 in order to couple the
core member 534, or the entire composite panel to which the core
member 534 belongs, to another object, including, but not limited
to adjacent core members 534 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 the core
member 534 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 and outer sheets 30, 32
are attached to the core member 534 including the apertures 40 and
the aperture-free portions 550, 552, rivet-receiving holes may be
punched through the formed composite panel (i.e., the inner sheet
30, the aperture-free portions 550, 552 of the core member 534, and
the outer sheet 32) such that rivets may then be received through
such rivet-receiving holes.
[0049] Looking to FIG. 12, for example, a portion of a sidewall 551
of a trailer includes a first composite panel 522 having the core
member 534, and an inner metal sheet 30 and an outer metal sheet 32
each coupled to the core member 534 via the use of an adhesive.
Illustratively, the sidewall 551 includes a second composite panel
524 similarly having the core member 534, and an inner metal sheet
30 and an outer metal 32 each coupled to the core member 534 via
the use of an adhesive. The first and second composite panels 522,
524 are adjacent to and spaced-apart from each other in a
side-by-side manner. A wall panel joint 560 including a logistics
member 562 and a splicing member 564 is provided to couple the
adjacent composite panels 522, 524 together. Illustratively, the
rivets 570 used to couple the wall panel joint 560 to the composite
panels 522, 524 are positioned within the side, aperture-free
portion 552 of each core member 534 of the panels 522, 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.
[0050] While the composite panels 522, 524 of FIG. 12 are joined
together by the wall panel joint 560 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 in FIG.
13, a portion of an alternative sidewall 581 includes a first
composite panel 582 and a second composite panel 584 each including
the core member 534, an inner metal sheet 30, and an outer metal
sheet 32. The composite panels 582, 584 are joined together by a
joint 590. In particular, the joint 590 is a shiplap joint. As
shown in FIG. 13, each composite panel 582, 584 includes an
overlapping skin member 592 for overlapping a portion of one of the
respective metal sheets 30, 32. Preferably, this overlapping skin
member 592 is integrally formed as part of the respective metal
sheet 30, 32 of each composite panel 582, 584. However, it is
envisioned that the overlapping skin member 590 may be a separate
member attached to the composite panels 582, 584 by suitable means.
Illustratively, the overlapping skin member 590 of each panel 582,
584 is provided for overlapping a portion of the respective inner
and outer sheets 30, 32 of the other, adjacent panel 582, 584. As
shown in FIG. 13, a side end portion of the respective sheets 30,
32 of the panels 582, 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 overlapping skin member 590, the surface formed by the
adjacent panels 582, 584 is substantially flush. This prevents the
overlapping skin members 592 from being snagged by an outside
object. A conventional rivet member 594 is then engaged through
aligned rivet-receiving holes provided through the overlapping skin
member 592 of the first composite panel 582 and the stepped end
portion of the second composite panel 584. A second conventional
rivet member 595 is engaged through aligned rivet-receiving holes
provided through the stepped end portion of the first composite
panel 582 and the overlapping skin member 592 of the second
composite panel 584. Illustratively, the rivets 594, 595 used to
couple the composite panels 582, 584 together are positioned within
the side, aperture-free portion 552 of each core member 534 of the
panels 582, 584. In other words, the stepped end portions of the
first and second composite panels 582, 584 include the
aperture-free portions 552 of the core member 534. 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.
[0051] It should be understood that the aperture-free portions 550,
552 of the foam core 534 of the composite panels disclosed herein
are free of apertures prior to the process of being joined to
adjacent composite panels. The aperture-free portions 550, 552
provide suitable aperture-free areas or portions of the composite
panels for having a rivet-receiving hole formed therethrough. In
other words, the apertures 40 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 and outer
sheets 30, 32 and are not only formed through the foam core
contrary to the apertures 40 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 portions
550, 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.
[0052] Illustratively, the pattern of the apertures 40 of the core
member 534 is different than the pattern of the apertures 40 of the
core member 34 shown in FIGS. 3 and 4. In particular, the pattern
of the apertures 534 of the core member 534 includes vertical and
horizontal rows of apertures 40 that are all aligned with each
other. In other words, every vertical row of apertures 40 of the
core member 534 is aligned with every adjacent vertical row of
apertures 40 of the core member 534. Further, every horizontal row
of apertures 40 of the core member 534 is aligned with every
adjacent horizontal row of apertures 40 of the core member 534.
However, the pattern of the apertures 40 of the core member 34
includes staggered, or offset, vertical and horizontal rows of
apertures 40, as shown in FIG. 4, such that every other vertical
row of apertures 40 of the core member 34 is aligned with every
other (and not every adjacent) vertical row of apertures 40 of the
core member 34 and every horizontal row of apertures 40 of the core
member 34 is aligned with every other (and not every adjacent)
horizontal row of apertures 40 of the core member 34.
Illustratively, while the specific patterns of apertures 40 are
shown in the core member 34 and the core member 534, 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.
[0053] While the particular apertures 40 of each of the core
members 34, 534 are circular in shape, it should be understood that
the members 34, 534 may include apertures 40 of any shape, such as
square, rectangular, triangular, oval, etc. Further, it should be
understood that the core members 34, 534 may each include apertures
of any suitable size having any suitable dimensions. Finally, while
the core members 34, 534 each include an array of apertures 40
which are all of the same shape and size, it should be understood
that the core members 34, 534 may include apertures of varying
dimension, size, and/or shape. In other words, while the apertures
40 of the illustrative core members 34, 534 are all of uniform
shape and size, the core members 34, 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 the
core members 34, 534 may be different and optimized according to
specific production process and performance specifications.
Finally, while the apertures 40 of each of the core members 34, 534
are shown to be spaced a particular distance apart from each other
that is generally uniform, it should be understood that the core
members 34, 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.
[0054] Looking to FIG. 5, for example, an alternative core member
134 is similar to the core members 34, 534. As such, like reference
numerals are used to denote like components. Rather than the
circular-shaped apertures 40 of the core members 34, 534, the core
member 134 includes a plurality of generally diamond-shaped
apertures 140. Illustratively, the diamond-shaped apertures 140 are
approximately % inch to 3/8 inch wide and 1/2 inch to 3/4 inch
tall. However, the apertures 140 may have any suitable height
and/or width. As discussed above in regard to the apertures 40, the
apertures 140 extend through the entire thickness of the core
member 134 from the outside surface 42 to the inside surface 44 of
the core member 134.
[0055] Looking now to FIG. 6, an illustrative process or method 150
for making the composite panel 22 is schematically illustrated.
Illustratively, a foamed core sheet 80 is first made by mixing
foaming beads or pellets 82 with thermal plastic resin beads or
pellets 84. These pellets 82, 84 are mixed in a mixing chamber 86
using an auger (not shown). The foaming pellets 82 have a gas
therein, such as carbon dioxide or nitrogen, for example. The mixed
pellets 82, 84 are subjected to heat in a hot die chamber 88 and
the foaming pellets 82 activate and produce carbon dioxide or
nitrogen to foam the mixture. The mixture is then extruded into a
layer by an extruder 90 to form the foamed core 80. Illustratively,
the foamed core sheet 80 is approximately 350.degree. F. upon
leaving the extruder 90. 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 foamed core 80, 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 the method 150 of making the composite panel 22 includes
making the foamed core sheet 80, it should be understood that the
composite panel 22 may include a non-foamed core sheet as well.
[0056] Once the foamed core sheet 80 is formed, a first set of
rollers 92 advances the foamed core 80 to a rotary die cutter 94
including an upper roller punch 96 and a lower roller 98.
Illustratively, the rollers 92 are chilled rollers in order to cool
the hot, extruded foamed core sheet 80. Further illustratively, the
upper die roller punch 96 maybe an engraved steel cylinder on a
roll-fed press. As shown in FIG. 6, the upper die roller 96
includes roller mounted hollow punches, or protrusions, 100 having
a circular cross-section. These protrusions 100 operate to pierce
the foamed core sheet 80 as it is advanced between the upper die
roller 94 and the lower roller 96, The punches, or protrusions 100,
react against the bottom roller 98 on the opposite side of the
foamed core sheet 80. The protrusions 100 illustratively form the
apertures 40 into the foamed core sheet 80 in order to produce the
core member 34.
[0057] During the die cutting process, slugs of material 102
displaced from the core sheet 80 are produced. Illustratively, such
slugs of material 102 may be extracted from the bottom roller 98,
recycled, and reused to make additional core sheets or other
devices including foamed components as well.
[0058] Once the core member 34, including the apertures 40, is
formed, the core member 34 is advanced through a set of upper and
lower heated laminating rollers 104, 106 where the inner and outer
sheets 30, 32 are laminated to each respective inner and outer
surface 42, 44 of the core member 34. Illustratively, a layer of
flexible adhesive (not shown) may be applied to the inner surface
of each of the sheets 30, 32 prior to laminating the sheets 30, 32
to the core member 34. Alternatively, the layer of flexible
adhesive may be applied directly to the opposite surfaces 42, 44 of
the core member 34. Further alternatively, the opposite surfaces
42, 44 of the core member 34 may be treated with a spray adhesive
to create an adhesive bonding layer on the opposite surfaces 42, 44
such that the metal sheets 30, 32 may be directly bonded thereto.
Regardless of the type of adhesive used or the method by which the
adhesive is applied, the inner and outer metal sheets 30, 32 are
adhered to the core member 34 by the adhesive layer under pressure
in order to create the composite panel 22. Illustratively, after
being formed, composite panel 22 may be cut to any suitable
length.
[0059] Looking now to FIG. 7, an alternative process or method 250
for making the composite panel 22 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 foamed core sheet 80 is produced in
the same manner as that described above in regard to FIG. 6. Once
the foamed core sheet 80 is formed, the first set of rollers 92
advances the foamed core sheet 80 to a cam-actuated roller punch
cutter 194 which similarly operates to pierce the core sheet 80 in
order to form the apertures 40 therethrough. Illustratively, the
cam-actuated roller punch cutter 194 includes an upper roller 196
and a lower roller 198 against which the upper roller punch 196
reacts during the punch cutting process. The upper roller 196
includes a cam member 199 having cam-actuated hollow punches 200
coupled thereto. In use, the cam-actuated hollow punches 200 are
forced out through punch holes 202 formed in the roller punch 196
as the roller punch 196 is pivoted about its central axis. Further
illustratively, the lower roller 198 includes die buttons or
apertures 204 through which the core slugs 108 may pass for removal
from the process and subsequent recycling. Once the core member 34
is formed through the use of the cam-actuated roller punch cutter
194, the composite panel 22 is formed in the same or similar manner
as that described above with reference to FIG. 6.
[0060] In yet another method for producing the core member 34, 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 foamed core sheet 80 while making the
through-cuts in the foamed sheet 80 to form the apertures 40. 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 moving core sheet 80 for the next penetration
sequence. As shown in FIG. 10, for example, a method 650 for
producing the core member 534 is provided. Illustratively, the
foamed core sheet 80 is produced in the same manner as that
described above in regards to FIGS. 6 and 7. Once the foamed core
sheet 80 is formed, the first set of rollers 92 advances the foamed
core sheet 80 to a transversing punch 696. As noted above, the
first set of rollers 92 operate to cool the foamed core sheet 80 as
it leaves the extruder 90 and is moved toward the punch 696.
Illustratively, while only lower rollers 92 are shown in FIG. 10,
it should be understood that upper rollers 92 may be provided as
well. Further, it should be understood that while only a single
upper and lower roller 92 is shown in FIGS. 6 and 7, a plurality of
lower and/or upper rollers 92 may be provided in order to advance
and cool the foamed core sheet 80 from the extruder 90 to the
transversing punch cutter 696.
[0061] Once the foamed core sheet 80 is advanced to the
transversing punch 696, the transversing punch 696 similarly
operates to pierce the core sheet 80 in order to form the apertures
40 therethrough. Illustratively, the transversing punch 696
includes an upper platform 698 including the vertical punches 700
extending downwardly therefrom. The transversing punch 696
illustratively extends across a height of the foamed core sheet 80
from a top edge 50 of the sheet to a bottom edge 52 of the sheet.
The transversing punch 696 further includes a lower platform 702
coupled to the upper platform 698 for back and forth movement
(shown by arrow 652) therewith. Illustratively, the transversing
punch 696 rests on a table 704 for back and forth movement across
the width of the table 704.
[0062] As noted above, the foamed core sheet 80 is approximately
350.degree. F. upon leaving the extruder 90 and is illustratively
cooled by the chilled rollers 92 to approximately 250.degree. F.
when the transversing punch 696 forms the apertures 40 therein. As
this hot foamed core sheet 80 advances toward the punch 696, the
punch 696 moves back and forth along the table 704 while the
vertical punches 700 operate to pierce the core sheet 80 to form
the apertures 40 therethrough. The core slugs (not shown) produced
from piercing the core sheet 80 may fall below and be removed from
the process for subsequent recycling. Once the core member 534 is
formed through the use of the transversing punch 696, the composite
panel 522 (shown in FIG. 12) is formed in the same or similar
manner as that described above with reference to FIGS. 6 and 7.
[0063] Illustratively, and similar to that discussed above in FIGS.
6 and 7, the composite panels 22, 522 including the respective core
members 34, 534 are produced continuously in a line using a "hot"
foamed core sheet 80 of approximately 250.degree. F. The apertures
40 are formed in the foamed core sheet 80 while the foamed core
sheet 80 is still "hot." Illustratively, it should be understood
that the term "hot" should not be limited to a temperature of
approximately 250.degree. F., but rather should refer simply to a
foamed core sheet 80 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 foamed core sheet 80 may
affect the tolerances of the equipment used to the punch the
apertures 40 in the sheet 80. As such, the equipment, such as the
dies 94, 194 and the punch 696 may need to be cooled as they are
operating to pierce the apertures 40 in the foamed core sheet
80.
[0064] Looking now to FIG. 8, a method 350 for making a composite
panel 322 including the core member 134 shown in FIG. 5 is
schematically illustrated. Illustratively, much of the process
includes the same or similar steps as that described above with
reference to FIGS. 6 and 7; as such, like reference numerals are
used to denote like components. In particular, the foamed core
sheet 80 is produced in the same manner as that described above in
regards to FIGS. 6 and 7. Once the foamed core sheet 80 is formed,
the first set of rollers 92 advances the foamed core sheet 80 to a
rotary die cutter 294 including an upper die roller 296 and a lower
roller 298. As shown in FIG. 8, the upper die roller 296 includes
roller mounted protrusions 300 in the shape of knife-like blades.
Illustratively, the blades 300 are thin and slender and operate to
pierce the extruded foamed core sheet 80 in a predetermined pattern
as the foamed core sheet 80 is advanced between the upper die
roller 296 and the lower roller 298. The blades 300 react against
the bottom roller 298 to create slots 302 within the foamed core
80.
[0065] Looking still to FIG. 8, the roller mounted blades 300
operate to pierce the core sheet 80 in a regular pattern.
Illustratively, the slots 302 formed in the foamed core sheet 80
define a longitudinal axis that is parallel to the longitudinal
axis of the foamed core sheet 80. In other words, the length of the
slots 302 extends along the length of the foamed core sheet 80 such
that the slots 302 are also parallel to the upper and lower edges
81, 83 of the foamed core sheet 80. As is discussed below, while
the illustrative slots 302 extend along a length of the foamed core
sheet 30, it is within the scope of this disclosure form slots 302
which are not parallel to the length, or longitudinal axis, of the
foamed core sheet 80 and which are, therefore, angled relative to
the longitudinal axis of the foamed core sheet 80.
[0066] As opposed to the processes 150, 250 described above (and
shown schematically in FIGS. 6 and 7), the die cutting process 350
of FIG. 8 does not create or displace any slugs of material from
the core sheet 80. As such, illustratively, no such slugs of
material need be extracted from the bottom roller 298 for
subsequent recycling or reuse.
[0067] Once the slots 302 are formed in the core sheet 80, the
now-slotted core sheet 80 is then subjected to width-wise forces
310 to expand the core sheet 80 and the slots 302 formed therein to
create the generally diamond-shaped slots 140 of the core member
134. The expanding force 310 is applied at right angles to the core
process flow thereby creating the apertures 140 that are generally
diamond-shaped. In particular, as shown schematically in FIG. 8,
the width-wise forces 310 operated to exert an outward force on the
slotted core sheet 80 in outward directions perpendicular to the
longitudinal axis of the foamed core sheet 80. Such outward force
310 operates to increase the width of the slotted foamed core sheet
80 while also pulling apart the opposite edges 141, 143 defining
each slot 302 in order to form the generally diamond-shaped slots
140. This geometry and increased core width is illustratively
retained as the core member 134 is cooled. Illustratively, one or
both core sheet edges 81, 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 the core member 134 is formed through the use of the
die cutter 294, the composite panel 322 is formed in the same or
similar manner as that described above with reference to FIGS. 6
and 7.
[0068] Alternatively, it should be understood that rather than
passing the foamed core sheet 80 through the rotary die cutter 294,
as described above and shown in FIG. 8, the protrusions 300 may be
mounted to a bank of punches (not shown) which are actuated in a
vertical motion in synchronism with the moving core sheet 80 in
order to create the slots 302 in the sheet 80.
[0069] Looking now to FIG. 9, a method 450 for making another
composite panel 422 including an alternative core member 234 is
schematically illustrated. Illustratively, much of the process 450
includes the same or similar steps as that described above with
reference to FIGS. 6-8; as such, like reference numerals are used
to denote like components. In particular, the foamed core sheet 80
is produced in the same manner as that described above in regards
to FIGS. 6-8. Once the foamed core sheet 80 is formed, the first
set of rollers 92 advances the foamed core sheet 80 to a rotary die
cutter 394 including an upper die roller 396 and a lower roller
398. As shown in FIG. 9, the upper die roller 396 includes roller
mounted protrusions 400 in the shape of knife-like blades.
Illustratively, as opposed to the protrusions 300 of the upper die
roller 296 shown in FIG. 8, a longitudinal axis of the protrusions
400 is parallel to the longitudinal axis of the upper die roller
396 itself. Illustratively, the blades 400 are similarly thin and
slender and operate to pierce the extruded foamed core sheet 80 in
a predetermined pattern as the foamed core sheet 80 is advanced
between the upper die roller 396 and the lower roller 398. The
blades 400 react against the bottom roller 398 to create slots 402
within the foamed core 80.
[0070] Illustratively, the roller mounted blades 400 pierce the
core sheet 80 in a regular pattern to produce slots 402 at right
angles to the core edges 81, 83. In particular, the illustrative
slots 402 formed in the foamed core sheet 80 define a longitudinal
axis that is perpendicular to the longitudinal axis of the foamed
core sheet 80. In other words, the length of the slots 402 extends
perpendicularly to the length of the foamed core sheet 80 such that
the slots 402 are also perpendicular to the upper and lower edges
81, 83 of the foamed core sheet 80. Similar to the die cutting
process 350 of FIG. 8, little or no slugs of material are created
or displaced from the core sheet 80 when the slots 402 are
formed.
[0071] Once the slots 402 are formed in the foamed core sheet 80,
the now-slotted core sheet 80 is then passed through upper and
lower pull-rollers 406, 408. The pull-rollers 406, 408 operate to
subject the slotted core sheet 80 to length-wise, or tensile,
forces 410 in the direction of travel to expand the core sheet 80
and the slots 402 formed therein. Subjecting the slots 402 to these
tensile forces expands the slots 402 to create generally
diamond-shaped slots or apertures 240 of the core member 234. As
shown schematically in FIG. 9, the length-wise forces 410 operate
to exert a force on the slotted core sheet 80 along the length of
the sheet 80 to increase the length of the slotted foamed sheet 80
while also pulling apart the opposite edges 141, 143 defining each
slot 402 in order to form the generally diamond-shaped slots 240.
Illustratively, as opposed to the diamond-shaped slots 140 of the
core member 134 shown in FIGS. 5 and 8, a length of the
diamond-shaped slots 240 of the core member 234 is perpendicular to
the length of the core member 134. Once the core member 234 is
formed through the use of the die cutter 394, the composite panel
422 is formed in the same or similar manner as that described above
with reference to FIGS. 6-8.
[0072] Again, alternatively, it should be understood that rather
than passing the foamed core sheet 80 through the rotary die cutter
394, as described above and shown in FIG. 9, the protrusions 400
may be mounted to a bank of punches (not shown) which are actuated
in a vertical motion in synchronism with the moving core sheet 80
in order to create the slots 402 in the sheet 80.
[0073] 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 foamed
core members 34, 134, 534, includes apertures 40, 140 formed
through a thickness (i.e., from the outer surface 42 to the inner
surface 44) 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 edges 50, 52, 54. Alternatively, the
apertures of a core member of the present disclosure may be
spaced-apart from the top, bottom, and side edges 50, 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 the edges 50, 52, 54 of the
core member. In particular, a distance that is perpendicular from
any edge 50, 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.
* * * * *