Patent ID: 6119344
Filing Date: 2000-09-19
Classification: B29C,B29D,B29L,Y10T

Abstract:
A continuous method for forming a structure suitable for use as a core member comprising:cutting an elongated thermoplastic sheet structure into a plurality of plates each having a length defined by spaced apart ends, and a predefined width, at least one surface extending across said width, and a plurality of elongated passageways disposed in parallel relationship along said length, each of said elongated passageways having a longitudinal axis perpendicular to the width of said plates;assembling said plates in abutting relationship with one another to form a stack of said plates in which the elongated passageways in each plate are arranged in a common parallel direction with the respective ends of the plates being aligned in a common plane transverse to the longitudinal axes of the elongated passageways;continuously moving said stack of said plates to a first cutting station;transversely cutting said continuously moving stack of said plates at preselected spaced apart locations along the longitudinal axes of the elongated passageways of the plates thereby forming a plurality of transversely cut plates having spaced apart cut surfaces, and simultaneously fusing at least one of the cut surfaces of the cut plates with the cut surface of an adjacently disposed cut plate thereby forming a plurality of structures each having a continuous length, a width substantially equal to the predefined width of said plates, and a thickness substantially equal to the distance between said spaced apart locations;continuously moving said structures having a continuous length to a second cutting station; andcutting across the width of each of said continuous length structures at preselected intervals along the continuous length of each of the structures and separating said continuous length structures into separate structures having a defined length.