SANDWICH STRUCTURE

Abstract

A sandwich structure employs a core sheet including alternating peaks and valleys therein. In another aspect, a sandwich structure includes at least one metallic core and at least one adhesively bonded outer face sheet. Yet another aspect of a sandwich structure has raised ridges bridging between adjacent peaks in a core sheet in one direction but not in a perpendicular direction, thereby achieving different properties in the different sheet directions.

Claims

1. A method of making a vehicular trailer sandwich structure, the method comprising: (a) applying tension to a metallic core sheet; (b) forming alternating peaks and valleys in the core sheet during step (a); (c) forming raised ridges bridging between at least some of the peaks along a first direction but not along a perpendicular second direction during step (b); (d) the forming steps being done at ambient room temperature with embossing rollers which have rotational axes set at a fixed distance from each other during the forming steps; (e) applying an adhesive to substantially flat ends of the peaks after the forming steps; (f) pre-heating a metallic outer sheet and the core sheet after the application of the adhesive; (g) laminating the vehicular trailer sandwich structure under greater heat than in the pre-heating step, in an oven containing heaters to create at least an initial green curing of the bonded sandwich structure in 30 seconds or less; (h) cooling the laminated vehicular trailer sandwich structure in a cooling unit; (i) wherein out-of-plane shear strength of the core sheet is at least 1.05 times greater in a cross-feeding direction as compared to a manufacturing feed direction; and (j) wherein a length shrinkage factor of the core sheet, where a ratio of initial versus end formed length, is at least 1.08 along the manufacturing feed direction, which is greater than a shrinkage factor along the cross-feeding direction.

2. A method of making a sandwich structure, the method comprising: (a) applying tension to a core sheet while forming alternating peaks and valleys into the core sheet at ambient room temperature with embossing rollers; (b) applying an adhesive to outermost lands of the opposed peak and valley surfaces after forming the peaks and valleys in the core sheet between the embossing rollers; (c) pre-heating the outer sheets and core sheet after the application of the adhesive; and (d) laminating the assembled sheets under greater heat than in step (c) and under substantially uniform pressure.

3. The method of claim 2, wherein the laminating comprises laminating the outer facing sheets onto the lands of the core sheet at a pressure of at least 5 and less than 20 pounds per square foot.

4. The method of claim 2, further comprising cooling the laminated sheets with a cooling unit after the lamination.

5. The method of claim 2, further comprising: (a) creating an offset stepped peripheral flange between the outer face sheets without the core sheet located therebetween; and (b) hemming together the outer face sheets at the peripheral flange.

6. The method of claim 2, wherein the tension applied to the core sheet during the peak and valley forming is done with at least one pinch roller contacting the core sheet.

7. The method of claim 2, wherein the tension applied to the core sheet during the peak and valley forming is done with at least one biased pressure arm contacting the core sheet to create tension in only the feeding direction while the core sheet is being formed.

8. The method of claim 2, further comprising feeding individually cut blanks of the core sheet between the forming rollers which have rotational axes that are parallel and at a fixed positional spacing during the entire formation of the peaks and valleys within the core sheet.

9. The method of claim 2, wherein each embossing roller has a set of forming pins projecting at a free-standing height relative to a substantially cylindrical roller drum surface, the lateral diameter of each pin being no less than the free-standing height of the associated pin, and a radius located from the sidewall of each pin to the roller drum surface, and the forming of the peaks and valleys is free of a lubricant between the core sheet and the embossing rollers.

10. The method of claim 2, wherein the sheets are all aluminum, without foam therebetween.

11. The method of claim 2, wherein the sheets are all steel, without foam therebetween.

12. A method of making a sandwich structure, the method comprising applying tension to a core sheet while forming alternating peaks and valleys into the core sheet at ambient room temperature with forming rollers, and free of a lubricant between the core sheet and the forming rollers.

13. The method of claim 12, further comprising: (a) applying an adhesive to outermost lands of the opposed peak and valley surfaces after forming the peaks and valleys in the core sheet between the forming rollers; and (b) laminating outer facing sheets onto the lands of the core sheet at a pressure of less than 20 pounds per square foot.

14. The method of claim 13, further comprising: (a) pre-heating the stacked outer sheets and core sheet after the application of the adhesive; and (b) laminating the assembly under greater heat than in step (a) and under substantially uniform pressure; and (c) cooling the laminated sheets with a cooling unit after the lamination.

15. The method of claim 12, further comprising: (a) creating a peripheral flange between the outer face sheets without the core sheet located therebetween; and (b) hemming together the outer face sheets at the peripheral flange.

16. The method of claim 12, wherein the tension applied to the core sheet during the peak and valley forming is done with at least one pinch roller contacting the core sheet.

17. The method of claim 12, wherein the tension applied to the core sheet during the peak and valley forming is done with at least one biased pressure arm contacting the core sheet to create tension in only a feeding direction while the core sheet is being formed.

18. The method of claim 12, further comprising feeding individually cut blanks of the core sheet between the forming rollers which have rotational axes that are parallel and at a fixed positional spacing during the entire formation of the peaks and valleys within the core sheet.

19. The method of claim 12, wherein each of the forming rollers has a set of forming pins projecting at a free-standing height relative to a substantially cylindrical roller drum surface, the lateral diameter of each pin being no less than the free-standing height of the associated pin, and a radius located from the sidewall of each pin to the roller drum surface.

20. The method of claim 12, wherein out-of-plane shear stiffness of the core sheet is at least 1.3 times greater in a cross-feeding direction as compared to a manufacturing feed direction.

21. The method of claim 12, wherein out-of-plane shear strength of the core sheet is at least 1.05 times greater in a cross-feeding direction as compared to a manufacturing feed direction.

22. The method of claim 12, wherein a length shrinkage factor of the core sheet, where a ratio of initial versus end formed length, is at least 1.08 along a manufacturing feed direction, which is greater than a shrinkage factor along a cross-feeding direction.

23. The method of claim 12, further comprising configuring the sandwich for attachment to a vehicle trailer.

24. A method of making a sandwich structure, the method comprising: (a) forming alternating peaks and valleys into a metallic core sheet at ambient room temperature with forming rollers which have axes stationarily set at a fixed distance from each other during the complete forming operation; (b) applying an adhesive to the peaks after the forming of the peaks and valleys; (c) pre-heating a metallic outer sheet and the core sheet after the application of the adhesive; and (d) laminating the assembly under greater heat than in step (c), in an oven containing heaters to create at least an initial green curing of the bonded sandwich structure in 30 seconds or less.

25. The method of claim 24, wherein the laminating includes using at least one elongated belt to compress against at least one of the sheets at a pressure of at least 5 and less than 20 pounds per square foot.

26. The method of claim 24, further comprising: (a) bonding a second outer face sheet to the core sheet; (b) creating a bent peripheral flange between the outer face sheets without the core sheet located therebetween; and (c) securing together the outer face sheets at the peripheral flange.

27. The method of claim 24, further comprising: (a) continuously feeding the core sheet to the forming rollers from a coil of sheet metal; and (b) cooling the laminated sheets with a chiller or refrigerator.

28. The method of claim 24, further comprising: (a) feeding individually cut blanks of the core sheet between the forming rollers; and (b) cooling the laminated sheets with a chiller or refrigerator.

29. The method of claim 24, further comprising applying tension to the core sheet during the peak and valley forming with at least one pinch roller contacting the core sheet.

30. The method of claim 24, further comprising applying tension to the core sheet during the peak and valley forming with at least one biased pressure arm contacting the core sheet to create tension in only the feeding direction while the core sheet is being formed.

31. The method of claim 24, wherein each of the forming rollers has a set of forming pins projecting at a free-standing height relative to a substantially cylindrical roller drum surface, the lateral diameter of each pin being no less than the free-standing height of the associated pin, and a radius located from the sidewall of each pin to the roller drum surface.

32. The method of claim 24, wherein out-of-plane shear strength of the core sheet is at least 1.05 times greater in a cross-feeding direction as compared to a manufacturing feed direction.

33. The method of claim 24, wherein a length shrinkage factor of the core sheet, where a ratio of initial versus end formed length, is at least 1.08 along a manufacturing feed direction, which is greater than a shrinkage factor along a cross-feeding direction.

34. The method of claim 24, wherein out-of-plane shear stiffness of the core sheet is at least 1.3 times greater in a cross-feeding direction as compared to a manufacturing feed direction.

35. The method of claim 24, further comprising folding the sandwich along a crease elongated in a direction substantially parallel to a cross-feeding direction.

36. The method of claim 24, further comprising configuring the sandwich for attachment to a vehicle trailer.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0006] FIG. 1 is an exploded perspective view showing a sandwich structure;

[0007] FIG. 2 is a cross-sectional view, taken along line 2-2 of FIG. 1, showing the sandwich structure;

[0008] FIG. 3 is a true elevational view showing a formed core sheet employed in the sandwich structure;

[0009] FIG. 4A is a cross-sectional view, taken along line 4A-4A of FIG. 3, showing the core sheet;

[0010] FIG. 4B is a cross-sectional view, taken along line 4B-4B of FIG. 3, showing the core sheet;

[0011] FIGS. 5A and 5B are graphs showing features of the core sheet;

[0012] FIG. 6A is a diagrammatic view showing a first embodiment manufacturing process for creating the sandwich structure;

[0013] FIGS. 6B and 6C are diagrammatic side views showing different tensioning configurations employed in the manufacturing processes;

[0014] FIG. 7 is an enlarged side elevational view showing pins on an embossing roller employed in the manufacturing processes;

[0015] FIG. 8 is a true view showing the pins on the embossing roller of FIG. 7;

[0016] FIG. 9 is a partial front elevational view showing the interrelationship of pins extending from cooperating embossing rollers used in the manufacturing processes;

[0017] FIG. 10 is an enlarged side elevational view showing one of the embossing roller pins;

[0018] FIG. 11 is a diagrammatic showing a second embodiment manufacturing process for creating the sandwich structure;

[0019] FIGS. 12A-12D are a series of cross-sectional views showing the process to make the sandwich structure with an optional peripheral flange;

[0020] FIGS. 13A and 13B are a series of cross-sectional views showing the sandwich structure with an optional hem flange;

[0021] FIGS. 14A and 14B are a series of cross-sectional views showing the sandwich structure with an interlocking tongue-and-groove flange;

[0022] FIG. 15 is a cross-sectional view showing an arcuately curved sandwich structure;

[0023] FIG. 16 is a cross-sectional view showing a configuration of a stacked core sandwich structure;

[0024] FIG. 17 is a cross-sectional view showing another configuration of a stacked core sandwich structure;

[0025] FIGS. 18A and 18B are a series of cross-sectional views showing foam employed in a sandwich structure;

[0026] FIG. 19 is a cross-sectional view showing a variation of a foam-filled sandwich structure;

[0027] FIG. 20 is a cross-sectional view showing a folded configuration of a sandwich structure;

[0028] FIG. 21 is an enlarged fragmentary view showing a corner of the folded configuration of the sandwich structure of FIG. 20;

[0029] FIG. 22 is a cross-sectional view showing a foam-filled variation of the folded sandwich structure of FIG. 20;

[0030] FIG. 23 is a cross-sectional view showing a different foam-filled configuration of the folded sandwich structure of FIG. 20;

[0031] FIG. 24 shows a mold used to curve the sandwich structure of FIG. 15;

[0032] FIG. 25 shows a circular-cylindrical configuration of a sandwich structure;

[0033] FIG. 26 is a side elevational view showing a truck and trailer employing the sandwich structure;

[0034] FIG. 27 is a perspective view showing a building wall and floor employing the sandwich structure; and

[0035] FIG. 28 is a true elevational view showing a movable garage door employing the sandwich structure.

DETAILED DESCRIPTION

[0036] A sandwich structure 31 can be observed in FIGS. 1-4B. Sandwich structure 31 includes a first generally flat, outer face sheet 33, a middle core sheet 35 and an opposite second generally flat, outer face sheet 37. Furthermore, core sheet 35 includes alternating peaks 39 and valleys 41, the external surface of each being defined by a generally flat land 43. Moreover, raised ridges 45 bridge or span between adjacent peaks 39 along a first width direction W but not in the perpendicular length direction L, where a more abrupt and steeply angled depression 47 is formed. Depressions 47 are located between adjacent peaks 39 along second direction L although each depression is elongated parallel to ridges 45 since the depressions are created on the back side of the ridges when the core sheet is formed into the desired contours from an initially flat workpiece sheet. Each ridge 45 is slightly lower than the generally flat lands 43 of the neighboring peaks 39. Sheets 33, 35 and 37 are preferably metallic, such as low carbon steel or aluminum, but any or all of these sheets may alternately be stainless steel or other metallic materials although many of the preferred manufacturing steps and final product properties may be different and less desirable. The metal grain structure is also different in the roll/feeding direction L of core sheet 35 than in the cross-roll/cross-feeding direction W.

[0037] The placement of ridges 45 and depressions 47 between the alternating peaks and valleys of core sheet 35 give the core sheet asymmetrical properties or characteristics after and during forming. For example, a length shrinkage factor fs, which is the initial core sheet length versus the formed end sheet length, is at least 1.08, and more preferably at least 1.10 in the roll direction L, as compared to a shrinkage factor fs of approximately 1.0 in the cross-roll/cross-feeding direction W. Furthermore, an out-of-plane shear stiffness of core sheet 35 is at least 1.3 times greater, and more preferably at least 1.4 times greater in the cross-roll/cross-feeding direction W, as compared to the roll/feeding direction L:

[L]G.sub.WT/G.sub.LT1.3

Additionally, an out-of-plane shear strength of core sheet 35 is at least 1.05 times greater, and more preferably at least 1.1 times greater in the cross-roll/cross-feeding direction W, as compared to the roll/feeding direction L:

[L].sub.WT/.sub.LT1.05

[0038] These characteristics are believed to exhibit the data plots shown in the graph of FIG. 5B. In other words, the formed core sheet 35 can be torqued or flexed about an axis parallel to direction W considerably easily than in the perpendicular direction about an axis parallel to direction L due to the ridge and depression orientation and positioning. This can be advantageously employed during the manufacturing and folded part shaping as will be described in greater detail hereinafter. It should be appreciated that the core sheet thickness will vary after it is formed. This asymmetrical core formation is very different than the symmetry desired in prior constructions.

[0039] The compressive strength of the present sandwich structure 31, where the outer sheets are bonded to the core sheet, across the cross-sectional thickness (as viewed in FIG. 2) is estimated as shown in the graph of FIG. 5A. The relative density of this particular sandwich core layer can be calculated as followed:

[00001]${}^{*}=\frac{f_S.Math.t_C}{C}$

where t.sub.c is the initial sheet thickness of the core layer, C denotes the core layer height and f.sub.s is the shrinkage factor in the length direction L. Thus, the asymmetrical nature of the periodic array of peak and valley cells or dimples, as connected in one direction by raised ridges and separated in the other by steep depressions, advantageously provides for different directional forming and final product properties and characteristics.

[0040] FIG. 6A illustrates a first manufacturing process and equipment used to manufacture sandwich structure 31. In this configuration, a coil of elongated core sheet metal 35 rotates about an axis 61 affixed to a support frame or machine for dispensing same. Core sheet 35 is continuously fed along direction L into tensioning pinch rollers 63 and then between a pair of embossing or forming rollers 65 which rotate about their respective axes 67. Axes 67 of embossing rollers 65 are stationarily set at a fixed distance from each other during the complete forming of each core sheet 35 and not adjusted during forming operation. It should be appreciated that one or both of these axes 67 can be moved for maintenance or initial embossing roller setup, however, it is not envisioned that the spacing between embossing rollers 65 change while forming the peaks and valleys of the core sheet, thereby providing tolerance consistence and repeatability within a single part and part-to-part.

[0041] A trailing set of tension pinch rotters 69 are provided downstream of embossing rollers 65. Alternately, mud-flap-like pressure arms 71 may flexibly extend from the machine housing 73 before and/or after embossing roller 65 in either of the combinations shown in FIGS. 6B or 6C. Each pressure arm 71 may be flexible or rigid with a proximal hinge and biasing spring. Pressure arms 71 and/or tensioning rollers 63 and 69 may be interchanged in order to best provide some tension and friction adjacent upstream and downstream sections of core sheet 35 as the peaks and valleys are being formed therein by embossing rollers 65. It is noteworthy, however, that no lateral or side sheet tensioning is necessary in order to provide the shrinkage factor difference ideally desired to prevent sheet metal tearing during the forming; while side tensioning or clamping may be used, it will not see some of the desired advantages.

[0042] The shape of forming pins 81 can best be observed in FIGS. 7-10. Each pin has a generally circular-cylindrical sidewall 83 with a diameter 85 of about 0.668 inch and a center point-to-center point spacing 87 of about 1.0 inch. Furthermore, a total height 89 of each pin is about 0.536 inch away from a circular-cylindrical surface 91 of a drum of each embossing roll 65 (see FIG. 6B). A free-standing dimension 93 between a ridge-forming section and a top of adjacent pins is approximately 0.433 inch while a feed direction pin-to-pin center point spacing 95 is about 1.0 inch. A valley forming top flat dimension 97 is approximately 0.220 inch, a distal corner radius 99 is about 0.224 inch, and a lower radius or fillet between a proximal sidewall 83 and a cylindrical drum surface 91 has a radius dimension 101 of approximately 0.157 inch. Moreover, a radius 103 is about 0.118 inch while a reverse radius 105 is about 0.157 inch. Finally, a dimension 107 is approximately 0.433 inch. Accordingly, it can be observed that there are essentially no sharp corners on any portion of each embossing pin 81 or the workpiece contacting area of drum surface 91, while a diameter of each pin is no less than the height of each pin projecting off of the drum for commercial low carbon steel and for aluminum. The pin diameter may be less than the height for a more brittle metal like stainless steel. Nevertheless, the pin diameter should always be greater than the free-standing height 93 for all metal workpiece sheet types to deter tearing. While the exact dimensions may vary depending upon the workpiece material type and sandwich properties desired, the relative dimensional ratios advantageously prevent sheet tearing during manufacturing while also maximizing crush strength and resistance between the peaks and valleys. The embossing rollers are made of tool steel then hardened in order to reduce wear without a need for a workpiece lubricant.

[0043] Returning to FIG. 6A, a conveyor 129 moves core sheet 35 into coating rollers 121 which have a curtain of liquid adhesive 123 flowing thereon from feeding hoppers 125 or pipes at an adhesive station. Rollers 121 transport the liquid adhesive onto lands 43 (see FIGS. 3 and 4A) which are essentially the only portions of the core sheet that are adhesively coated, preferably on both sides of the core sheet. Alternately and less preferably, adhesive may be sprayed or brushed onto the lands of the core sheet either in an automated or manually operated manner. It is noteworthy that core sheet 35 is formed and adhesive applied to it at ambient room temperature, humidity and pressure.

[0044] Thereafter, coils of generally flat outer face sheets 33 and 37 are continuously fed in direction L and stacked above and below core sheet 35. A preheating oven 127 heats the sheet and more particularly, the adhesive, to a temperature generally between 200-300 F. and more desirably to about 250. Preheating oven 127 uses top and bottom flames, electrically resistive elements or lights, and is positioned downstream of adhesive coating rollers 121.

[0045] A lower vinyl conveyor belt 128 thereafter moves the still continuously elongated but now pre-heated sandwich sheets in a laminating station which includes an upper endless vinyl belt 130 downward applying less than 20 pounds per square foot of pressure, and more preferably about five pounds per square foot of pressure along thickness T. The lamination station is within an insulated box or oven 131 containing at less 10, and more preferably 30, upper tubular bars 132 and the same quantity of lower tubular bars for radiating blown heat therefrom to heat up sheets to a temperature of 350-450 F., and more desirably about 400 F., for 30 seconds or less, and even more preferably 15 seconds or less. This causes very quick initial green curing of the bonded sandwich structure 31. Furthermore, belts 128 and 130 each have a feeding length L of at least 10 feet and more preferably at least 30 feet, thereby providing a generally uniform but gentle laminating pressure to one or more elongated sandwich structures therebetween. Subsequently, a fan blows air through liquid transporting chiller or refrigeration tubes in a cooling unit or station 133 downstream of the laminating belts, whereafter, cutting blades 135, water jet cutters, laser cutters or the like are employed to cut the finished and cooled sandwich structure 31 into the desired lengths, which are subsequently packaged and shipped to a customer.

[0046] FIG. 11 shows a different processing configuration used for pre-cut blanks or sheets. In this version, the pre-cut core sheet 35 is manually or automatically machine fed into forming or embossing rollers 65 via a table or shelf 141 projecting in the feeding direction from an embossing machine housing 73. Such a shelf or table arrangement can be used instead of or in addition to roller or belt conveyors 129, as illustrated in FIG. 6. FIG. 11 further shows a pair of pressure arms 71 upstream and downstream of embossing rollers 75.

[0047] Thereafter, the formed core sheet 35 is adhesively coated by coating rollers 121. Core sheet 35 is then manually or automatically stacked between the pre-cut outer layer sheets 33 and 37. The sandwiched sheets are subsequently fed into pre-heating oven 127, and the sandwich is then elevated in temperature while being laminated or compressed between laminating belts 128 and 130 to cause sufficient bonding therebetween, as discussed for FIG. 6A. These laminated sheets are then optionally cooled by the cooling unit 133 and then packaged. Various fixtures or pins may be employed to properly align the sheets when they are stacked together and laminated.

[0048] Another feature of the present sandwich structure 31 can be observed in FIGS. 12A-12D. In this configuration, outer sheet 33 has a peripheral segment 201 formed or bent into an offset L-shaped flange 203 which mates against an extending flange segment 205 of opposite face sheet 37. Adhesive 123 bonds together flanges 203 and 205 without core 35 being located therebetween. Thus, during the manufacturing, the core sheet is intentionally cut short of the peripheral edge and flange segments of the adjacent outer face sheets prior to stacking and laminating. Attaching flanges 203 and 205 can be provided on one or all peripheral edges of sandwich 31 depending upon the end use desired. It is alternately envisioned that both outer face sheets may also be bent in the offset manner shown with regard to face sheet 33, depending upon the desired location of the final sandwich flange relative to a component attached thereto.

[0049] FIGS. 13A and 13B illustrate another variation where flanges 203 and 205 are created in outer face sheets 33 and 37, respectively, and without core sheet 35 between the flanges. In this version, however, a hemming tool folds flanges 203 and 205 upon themselves in a generally U-shaped manner and interlocks them together to create a hemmed joint or seam around a peripheral portion thereof; adhesive may not be necessary between the flanges in such an arrangement.

[0050] As can be observed in 14A and 14B, yet another variation of a sandwich 31 includes outer face sheets 33 and 37 sandwiching a formed core sheet 35 therebetween, bonded by adhesive 123 or the like. Adhesive 123, but not core sheet 35, is present at flanges 203 and 205. In this construction, peripheral flanges 203 and 205 of the face sheets are angularly offset and upturned. This creates a generally U-shaped and open hook-like configuration. Thus, a pair of oppositely oriented hook-like flanges 203 and 205 provide a tongue-and-groove interlocking joint 211 between mating sandwich structures 31. This advantageously allows for removability of adjacent panels which is ideally suited for use as a wall structure or partition 213 in an office, residential or industrial building 215 (see FIG. 27). If adhesive is employed between the tongue-and-groove joints 211 then both mechanical and adhesive connections are provided between the adjacent sandwich structures 31 for permanent attachment together such as for a ceiling or floor 217 in building 215 (see FIG. 27), side, ceiling or floor walls for a vehicular trailer 219 (see FIG. 26), or body panels 221 in a land, water or air vehicle 221 (see FIG. 26).

[0051] Referring now to FIGS. 16 and 17, multiple core sheets, each having formed peaks and valleys, are employed between outer face sheets 33 and 37. In FIG. 16, the peaks and valleys of each core 35, 35 and 35 are generally aligned with each other in both roll and cross-roll directions. Intermediate flat sheets 231 and 233 are positioned between the stacked core sheets 35, 35 and 35 with adhesive 123 bonding between the adjacent sheets. The FIG. 17 version only uses outer face sheets 33 and 37 without intermediate sheets between the adjacent touching core sheets 35, 35 and 35. But in this construction, the peaks and valleys of each adjacent core sheet must be offset from the other adjacent sheet so that a land on a peak of one is adhered by adhesive 123 to a land on the valley of the other, and so on. It should be appreciated that least three formed core layers are employed between a pair of outer generally flat face sheets, such that four, five or more cores can be stacked therebetween depending upon the compressive strength and thickness desired.

[0052] FIGS. 18A and 18B show a pelletized or granulated, substantially solid form of a foam 251 located in each valley of core sheet 35 prior to lamination of an outer face sheet 33 thereon. Foam 251 is preferably either an expandable structural foam or an expandable insulating foam, which also serves to adhere core sheet 35 to outer sheet 33 instead of requiring a separate adhesive coating station. Exemplary structural and insulating foam materials can be found in U.S. Pat. No. 6,846,559 entitled Activatable Material which issued to Czaplicki et al. on Jan. 25, 2005, and U.S. Pat. No. 3,950,259 entitled Pourable Granulated Siliceous Insulation which issued to Pallo et al. on Apr. 13, 1976, both of which are incorporated by reference herein.

[0053] FIG. 19 illustrates a version with expandable foam located on both sides of metallic core sheet 35. In this version, the foam may be injected into the finished sandwich or molded onto both sides of core sheet prior to placement of the outer face sheets thereon.

[0054] FIGS. 20 and 21 illustrate sandwich structure 31 folded at three corners such that each crease 271 created thereby is elongated in alignment with a series of aligned depressions 47 (see FIGS. 3 and 4A) in order to maximize the flexibility in this direction. This also minimizes structural degradation of the peaks and valleys adjacent to each side of crease 271. Sandwich structure 31 can be bent in this manner on a simple bending press, such that a pair of adjacent walls have a generally perpendicular relative orientation about the apex at crease 271. One or more bends can thereby be created in a single part. For example, the part of FIG. 20 illustrates an enclosed box section having a generally polygonal or square exterior shape. Moreover, one or more mating flanges 203/205 may be provided at the adjacent peripheral ends for adhesive, welding, spot welding, riveting, screwing or other fastening.

[0055] FIG. 22 shows a folded box-like construction of sandwich 31. In this construction, however, an expandable foam 251 is located between outer face sheets 33 and 37 so as to encapsulate both sides of core sheet 35. In contrast, FIG. 23 shows an expandable foam 251 entirely filling the center and closed area defined by sandwich 31. If a structural foam 251 is employed then this foam and sandwich arrangement is ideally suited for light weight and extremely stiff structural pillars and trusses within a building, upstanding corner framing in a trailer, struts in an aircraft or the like.

[0056] Finally, a curved exterior shape can be created from sandwich structure 31, as is shown in FIGS. 15, 24 and 25. After lamination of outer face sheets 33 and 37 onto core sheet 35, a sandwich can be re-heated to about 302 F. for 15-30 minutes, by way of a non-limiting example, in order to melt the adhesive therebetween. The heated sandwich is then placed into a mold 301 having arcuately shaped and matching interior cavity faces 303, where moderate pressure is applied. Gradually, each sheet will move and slide relative to the others until the desired curved formation is obtained and then the adhesive is allowed to re-cool and set back up in a strongly bonded manner. This can provide either a gentle arcuately curved arrangement as shown in FIGS. 15 and 24 or, taken to its extreme, a fully circular-cylindrical arrangement with mating edge flanges, such as that shown in FIG. 25.

[0057] FIG. 28 shows another variation wherein any of the previously disclosed sandwich constructions is employed as one or more sections of a door 311, such as a movable garage door with multiples of adjacent sandwich panels hinged together. The sandwich may alternately be a smaller building door like that shown in FIG. 27 or a door for trailer 219 in FIG. 26. It should also be appreciated that any of the preceding embodiments and features thereof can be mixed and matched with any of the others depending upon the final product and processing characteristics desired.

[0058] While various embodiments of the present invention have been disclosed, it should also be appreciated that other variations may be employed. For example, welding, spot welding or blind riveting may be used instead of adhesive bonding between the adjacent sheets, but many of the present weight, cost and quick assembly advantages may not be realized. Additionally, other dimensions and shapes may be provided for the core sheet, embossing pins and the like; however, many of the manufacturing advantages and property strengths will not be achieved. Variations are not to be regarded as a departure from the present disclosure, and all such modifications are intended to be included within the scope and spirit of the present invention.