Importance

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Abstract

A modular light-weight structural panel is made by stacking in consecutive alternation a number of long, narrow foam plastic filler elements with a number of substantially flat lattice structures. The sub-assembly is laterally compressed to cause each of the lattice structures to be pressed into and partially embedded in mutually abutting surfaces of adjacent ones of the filler elements. While in such compressed condition cross members are welded to side portions of the lattice structures that protrude beyond the filler element surfaces to thereby hold the assembly in its pressed condition with the lattice structures embedded in the filler elements and surfaces of adjacent filler elements in close face-to-face contact with one another. Thereafter, the filler elements are bodily displaced toward one side of the panel so that outer sides of the filler elements are positioned substantially at the panel side and inner sides of the filler elements are displaced inwardly of the panel side, thereby enabling a relatively thick exterior coating to be applied to one side of the panel and a relatively thin interior coating or finishing sheet to be applied to the other side. In a hollow core embodiment, each filler element is made in two sections which, after welding of the cross members, are outwardly displaced relative to each other to position both sections of each filler element at an outer surface of the panel, thereby providing a hollow core panel, both sides of which may be coated with relatively thin interior coatings.

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First Claim