Patent Publication Number: US-10309148-B2

Title: Polycarbonate honeycomb core door and method of making same

Description:
RELATED APPLICATIONS 
     This application is related to U.S. patent application Ser. No. 15/662,936 filed on Jul. 28, 2017 entitled “Insulated Reinforced Door Panel and Door Frame with Thermal Break;” U.S. patent application Ser. No. 15/679,273, filed on Aug. 17, 2017, entitled “Insulated Fiber Reinforced Door Panel and Method of Making Same” and U.S. patent application Ser. No. 15/710,909 filed on even date herewith entitled “Fiber Reinforced Plastic Door with Polycarbonate Ballistic Core and Method of Making Same.” 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to insulated structural panels that may be used as doors, and in particular, door panels having improved rigidity, blast and ballistic resistance, thermal efficiency, aesthetics and manufacturability. 
     2. Description of Related Art 
     Commercial hollow metal and wood door cores typically consist of Polystyrenes, Polyurethanes, Polyisocyanurate, Honeycomb (Kraft paper), Stave Lumber, Particleboard, Agra-Fiber, Mineral Core, Rock Wool, Fiberglass, Blast-Resistant, and Bullet-Resistant materials. Each core type has a different performance function and price point. Maintaining all of these core types adds complexity, inventory, and costs that could be reduced. Steel reinforcements and steel end caps may also be employed, yet they are conductive for thermal and electrical energy. These steel reinforcements may not be dimensionally stable under thermal loading, negatively impacting the energy efficiency of the door opening thermal performance for preventing thermal transfer. The steel is also vulnerable to corrosion and rusting, and greatly increases the total weight of the door. This added weight impacts hardware wear and tear, product lifestyle, and cost of ownership. The weight of components and finished door total weight also impacts freight and shipment costs of raw components, and finished goods shipment cost. 
     SUMMARY 
     Bearing in mind the problems and deficiencies of the prior art, it is therefore an object of the present invention to provide a structural panel that may be used as a door with improved structural integrity, blast- and ballistic-resistance, and/or thermal efficiency. 
     It is another object of the present invention to provide a structural panel which provides a reduction in weight without sacrificing structural strength and blast- and ballistic-resistance (if employed). 
     It is yet another object of the present invention to provide a structural panel which is dimensionally stable to reduce thermal bow effect. 
     Still another object of the present invention is to provide a structural panel which provides sound transmission class (STC) improvement. 
     A further object of the present invention is to provide a structural panel which provides improvement in thermal insulation and air infiltration. 
     The above and other objects, which will be apparent to those skilled in the art, are achieved in the present invention which is directed to a panel which may be used as a door. The panel comprises a shell having spaced first and second exterior panels and frame members adjacent edges of the panels. At least one polymeric sheet is between the first and second exterior panels, the at least one polymeric sheet being made of a thermoplastic material, and has a plurality of openings through a thickness thereof. The openings are spaced apart by flat wall portions of the polymeric sheet. 
     The panel may include a plurality of polymeric sheets. In an embodiment, the sheets are stacked with the openings of one sheet offset from the openings of an adjacent sheet, and the openings of one sheet are adjacent flat wall portions of the adjacent sheet. The polymeric sheet may be bonded to an adjacent exterior panel. The at least one polymeric sheet may be spaced from an adjacent exterior panel, and a foam insulation material may substantially fill all of the space therebetween. A plurality of polymeric sheets and a plurality of stiffeners may be disposed between the polymeric sheets. 
     An embodiment of the panel may further include securing stiffeners by a polymeric end cap made of a thermoplastic material, the end cap which has a plurality of openings through a thickness thereof. The ends of the stiffeners are received within the openings of the polymeric end cap, and the openings of the polymeric end cap are oriented 90° to the openings of the polymeric sheets. A foam insulation material may fill substantially all of the space between the polymeric sheets, stiffeners, and frame members in the shell interior portion. 
     The present invention also provides a method of making a panel which may be used as a door. First and second exterior panels and frame members are provided for a door shell. At least one polymeric sheet being made of a thermoplastic material is also provided. The polymeric sheet has a plurality of openings through a thickness thereof, the openings being spaced apart by flat wall portions of the polymeric sheet. The first and second exterior panels, frame members, and the at least one polymeric sheet are assembled to make a shell having spaced first and second exterior panels and frame members adjacent edges of the panels. The at least one polymeric sheet is between adjacent exterior panels and bonded to them. 
     The method may further include the at least one polymeric sheet being spaced apart from adjacent exterior panels, with a curable and hardenable foam insulation material injected therebetween. The insulation provides both thermal insulation and a chemical bond with the polymeric sheet and exterior panels when cured. The method may also include a plurality of polymeric sheets and a plurality of stiffeners comprising a thermally non-conductive fiber reinforced polymer. The plurality of stiffeners are assembled between the polymeric sheets. 
     The present invention also provides a structural panel which may be used as a door. A shell has spaced first and second exterior panels and frame members adjacent edges of the panels. At least one polymeric sheet is between the first and second exterior panels. The at least one polymeric sheet is made of a thermoplastic material and has a plurality of openings through a thickness thereof. The openings are spaced apart by flat wall portions of the polymeric sheet. At least one blast- or ballistic-resistant core layer is adjacent the at least one polymeric sheet. 
     An embodiment of the panel includes a plurality of polymeric sheets wherein the at least one blast- or ballistic-resistant core layer is between a pair of the polymeric sheets. The panel may further include a plurality of polymeric sheets wherein the sheets are stacked with the openings of one sheet being offset from the openings of an adjacent sheet. The openings of one sheet are adjacent flat wall portions of the adjacent sheet. The at least one polymeric sheet may further be bonded to an adjacent exterior panel. The at least one polymeric sheet may also be spaced from an adjacent exterior panel, with a foam insulation material filling substantially all of the space therebetween. 
     The present invention additionally provides a method of making a panel which may be used as a door. First and second exterior panels and frame members for a door shell are provided. The method also provides at least one polymeric sheet being made of a thermoplastic material and having a plurality of openings through a thickness thereof. The openings are spaced apart by flat wall portions of the polymeric sheet. At least one blast- or ballistic-resistant core layer is also provided. The first and second exterior panels, frame members, at least one polymeric sheet, and at least one blast- or ballistic-resistant core layer are assembled to make a shell having spaced first and second exterior panels and frame members adjacent edges of the panels. The at least one polymeric sheet is between adjacent exterior panels, and the at least one blast- or ballistic-resistant core layer is adjacent the at least one polymeric sheet. The at least one polymeric sheet is bonded to adjacent exterior panels. 
     The method may further provide a plurality of polymeric sheets, and assembling the at least one blast- or ballistic-resistant core layer between the polymeric sheets. The at least one polymeric sheet may be spaced from an adjacent exterior panel, and the method may further include injecting a curable and hardenable foam insulation material therebetween. When cured, the insulation provides both thermal insulation and a chemical bond with the polymeric sheet and exterior panels. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The figures are for illustration purposes only and are not drawn to scale. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which: 
         FIG. 1  is a front elevational view with partial cutaway of an embodiment of the door panel according to the present invention. 
         FIG. 2  is an end view of the lower frame member of the door panel of  FIG. 1 . 
         FIG. 3  is a perspective view of an embodiment of the honeycomb polycarbonate sheet used in the internal structure of the door panel of  FIG. 1 . 
         FIG. 4  is a perspective view with partial cutaway of the door panel of  FIG. 1 . 
         FIG. 5  is a perspective view of a FRP stiffener used in another embodiment of the door panel according to the present invention. 
         FIG. 6  is a front elevational view with partial cutaway of the other embodiment of the door panel employing the FRP stiffener of  FIG. 5 . 
         FIG. 7  is a cutaway end view along line  7 - 7  of the lower frame members of the door panel of  FIG. 6 . 
         FIG. 8  is a cutaway front elevational view with partial cutaway of an embodiment of the insulated, blast- and/or ballistic-resistant reinforced door panel according to the present invention. 
         FIG. 9  is a cross section of the lower frame member of the insulated reinforced door panel embodiment of  FIG. 8 . 
         FIG. 10  is an exploded perspective view of embodiments of the polymeric sheets and blast- and/or ballistic-resistant core for the door panel embodiment of  FIG. 8 . 
         FIG. 11  is a cutaway cross sectional view along line  11 - 11  of the optional layers of the door panel embodiment of  FIG. 8 . 
     
    
    
     DESCRIPTION OF EMBODIMENT(S) 
     In describing the preferred embodiment of the present invention, reference will be made herein to  FIGS. 1-11  of the drawings in which like numerals refer to like features of the invention. Reference will also be made to the general direction of orientation of the door panel  20  of the invention. 
     The drawings show alternate embodiments of the structural panel  20  of the present invention, which is in the embodiment shown a door panel. The door shell includes an inner panel  40  and a spaced outer panel  42  opposite the inner panel. The inner panel  40  and outer panel  42  form the exterior panels of the door, and may also be referred to as the door skin. The exterior panels may be made of any suitable sheet material, for example a metal or alloy such as about 14, 16, 18 or 20 gauge steel, a fiber reinforced plastic (FRP), wood or composite. The exterior panels may be flat or embossed. The door  20  includes door edges  48  extending between the periphery of the inner and outer panels. Upper and lower door edges  48  are formed by elongated upper and lower frame members  90 , which may have a “U” or “C” channel cross-section, to which the inner and outer panels  40 ,  42  are welded or otherwise adhered. Side door edges  48  also have a “U” or “C” cross-section  94 , which may be formed by folding the side edges of outer panel  42 . There may be provided in the frame members one or more slots or openings  98  for hanging panel  20  during the manufacturing process, such as when painting, and one or more slots or openings  96  for injecting foam insulation ( FIGS. 2, 7 and 9 ) (discussed further below). A preparation opening  70  for a lock and/or door handle may be provided, along with hinges  72  ( FIGS. 1 and 8 ) to secure the door to a door opening (not shown). Although the panel  20  is shown in use as a door, alternatively, the present invention may be used as a wall or other structural panel, without the door hardware. 
     In the interior portion of the shell between the inner and outer exterior panels there is disposed one or more planar polymeric sheet(s)  30 ,  30   a ,  30   b  made of a thermoplastic material, such as a polycarbonate, with opposite sides or walls. The polymeric sheet  30 ,  30   a ,  30   b  is formed with a honeycomb pattern having a plurality of regularly spaced, patterned openings or holes  32  between flat wall portions  33 , which openings may be molded in during forming of the thermoplastic, or otherwise formed through the thickness of the polymeric sheet. The openings  32  may have any desired cross-section, such as circular, square, rectangular or polygonal. The polymeric sheet  30 ,  30   a ,  30   b  is both thermally and electrically non-conductive. The sheet dimensions may be sized to fill substantially the entire interior of the panel volume, or may be of lesser width, height or thickness than the interior space formed by the panel skins and edges. The thermoplastic material and dead air space formed by the openings  32  provides thermal insulation through the panel thickness. If a plurality of stacked polymeric sheets of lesser thickness are used, to provide additional thermal insulation each sheet may be staggered or offset from the adjacent panel so that the holes or openings of one sheet are offset from those of the adjacent sheet, and are instead aligned with the polymeric wall between openings of an adjacent sheet. 
     In one embodiment ( FIGS. 1-4 ) no additional reinforcing is placed inside the panel, and the polymeric sheet may be adhered or bonded to the inside faces of the exterior panels or skins by a structural adhesive, applied either in a plurality of beads or sprayed on substantially the entire surface. If a plurality of stacked thinner polymeric sheets are employed, adhesive may be applied between each sheet. Optionally, a single polymeric sheet  30  may have a thinner dimension, for example 0.5 in. less than the interior dimension, and may be foamed in place. Spacers may be placed between the door panels or skins and the polymeric sheet  30  to form, for example, a 0.25 in. gap on each side, and a foam material may be pumped in on each side of the sheet  30  via openings  96 . This may be a curable and hardenable insulation material  60  which fills the interior cavities between polymeric sheet  30  and the inner and outer panels  40 ,  42  ( FIG. 4 ). The insulation material may be expanded foam such as polyurethane expanding foam available from BASF. The foam when cured acts to provide additional thermal insulation through the thickness of the panel. Additionally, the cured foam adheres to and acts to lock the polymeric sheet  30  in place to prevent movement thereof. The foam material may also be applied between adjacent sheets  30   a, b  if a plurality of thinner, stacked polymeric sheets are employed, and may encapsulate the polymeric sheet(s). 
     In another embodiment ( FIGS. 8-11 ) a pair of polymeric sheets are employed, and each polymeric sheet may be adhered or bonded to the inside faces of the exterior panels or skins by a structural adhesive, applied either in a plurality of beads or sprayed on substantially the entire surface. Optionally, spacers may be placed between the door panels or skins and each polymeric sheet  30   a, b  to form, for example, a 0.25 in. gap on each side, and a foam material may be pumped in on each side of the polymeric sheets  30   a ,  30   b  via openings  96 . This may be a curable and hardenable insulation material  60  which fills the interior cavities between polymeric sheet  30   a, b  and the inner and outer panels  40 ,  42  ( FIG. 4 ). The insulation material may be expanded foam such as polyurethane expanding foam available from BASF. The foam when cured acts to provide additional thermal insulation through the thickness of the panel. Additionally, the cured foam adheres to and acts to lock the polymeric sheet  30   a, b  in place to prevent movement thereof. The foam material may also be applied between adjacent sheets  30   a, b  if a plurality of thinner, stacked polymeric sheets are employed, and may encapsulate the polymeric sheet(s). 
     In the interior portion, between the polymeric sheets, one or more core layers of a blast-resistant or ballistic-resistant material  180  extend substantially between the door edges ( FIG. 10 ). The blast-resistant or anti-ballistic material  180  may be made of any suitable rigid or flexible sheet material, for example polymeric materials such as Kevlar or other aramids, Lexan, carbon-fiber composites, or traditional metal armor. The former materials add less mass to the door panel. The core layers may be provided to any desired blast- or ballistic-resistant standards, such as UL 762 ballistic standard, levels 1 through 8 or shotgun, ASTM F1642, ASTM F2927, UFC 4-010-01 9, GSA TS-01 Level C and D blast standard. The core layers may be made to conform to other standards for other properties, such as sound transmission class (STC), radio frequency (RF) shielding, or fire rating. For a typical 1¾ in. or 2 in. door, the thicknesses of the core layer(s) in combination with the polymeric sheet(s) may be selected to provide the most desirable properties to the desired sandwiched or hybrid specialty core. 
       FIGS. 5-7  show another embodiment of the insulated reinforced door panel  20 ′ of the present invention. The door shell again includes inner and outer panels  40  and  42 , and side, upper, and lower door edges  48 . 
     In the interior portion between the inner and outer exterior panels a plurality of spaced-apart elongated structural stiffeners  50  extend substantially between the door edges. Although stiffeners  50  are shown extending vertically from the top to the bottom edges of the door, they may extend horizontally from one side to the other, or in any other direction. The stiffeners may be made of a fiber reinforced polymer (FRP), such as glass fiber reinforced polymer (GFRP), aramid fiber reinforced polymer (AFRP), carbon fiber reinforced polymer (CFRP), or the like. FRP stiffeners are described in U.S. application Ser. No. 15/662,936, the disclosure of which is hereby incorporated by reference. The drawings show a FRP rod  50  which has glass fibers spirally wrapped  54  about the exterior ( FIG. 5 ). The FRP may be anisotropic or isotropic in mechanical properties, and generally has significantly higher tensile strength and lower modulus of elasticity than steel. As a result, a stiffener made of FRP may be made of comparable or greater strength than steel, with significantly lower mass. The FRP stiffener may be of any cross-section desired, such as circular or rectangular. 
     As shown, the FRP stiffener  50  is of a substantially circular configuration. The diameter of the stiffeners may typically be in the range of 0.25 in to 0.75 in., for example 0.375 in. or 0.5 in. The stiffener diameter may typically be in the range of 20% to 50% of the interior door thickness, and may be in the range of 20% to 30% thereof. The stiffeners  50  should be provided in configuration, number, and size to provide sufficient structural integrity to maintain the desired strength of the door. Stiffeners  50  are sized and spaced from inner and outer door panels  40 ,  42 , so a gap exists and there is no direct contact between the mid-portions of the stiffeners between ends  52  and the inner surface of the door panels or skins. 
     On one or either side of stiffeners  50  are disposed a polymeric sheet  30 , between the stiffeners and the interior of the panels or skins  40 ,  42  ( FIG. 6 ). Each sheet  30  may be of a thickness to fill either less than, or the entire, gap between the stiffeners and the panels or skins, for example, 0.5 in. each. The polymeric sheets  30  may be bonded to the adjacent door panels or skins  40 ,  42  in the manner described above in connection with the embodiment of  FIGS. 1-4 . To hold the stiffeners  50  in place within the door interior, the ends  52  are secured to positioning members shown as end caps  80 , which are themselves secured to frame members  90  at the top and bottom door edges  48 . Stiffeners  50  may be secured to frame members directly. In the embodiment shown, the end caps are formed from sections of the thermoplastic honeycomb sheets, and the stiffeners  50  are bonded into the openings  82  in the thermoplastic honeycomb end cap sections  80 . Thermoplastic honeycomb end caps are described in U.S. application Ser. No. 15/679,273, the disclosure of which is hereby incorporated by reference. The longitudinal axes passing through the centers of the end cap openings  82  are oriented 90° (perpendicular) to the longitudinal axes passing through the centers of polymeric sheet openings  82 . 
     The FRP rod ends  52  may be secured into the end cap openings with an adhesive, for example, epoxy. Alternatively, the stiffener ends  52  may be mechanically locked in position by a tight sliding interference fit into the end cap openings  82 . Other bonding methods and materials may alternatively or additionally be used to secure the stiffener ends  52 , including but not limited to mechanical fasteners, such as a lock washer. Both ends of the stiffeners are secured to the end caps, and similar end caps  80  (not shown) are provided at the top end of door panel  20 ′ secured to top frame  90  at top edge  48  between door panels or skins  40 ,  42 . 
     Insulation material  60  may be inserted between adjacent stiffeners and to fill the interior cavity formed between polymeric sheets  30 , such as the aforedescribed expanded foam. The foam when cured acts to provide thermal insulation through the thickness of the panel. Additionally, the cured foam adheres to and acts to lock the mid-sections of stiffeners  50  in place, between the ends  52 , to prevent movement of the stiffeners from side-to-side, in the directions of the panel side frame members  94 . The FRP stiffener composition may also be selected so that the insulation material  60  when cured chemically bonds to the FRP stiffener surface, so that the stiffeners and insulation are integral with one another. The use of FRP for the stiffeners also improves the thermal insulation of the door, since the FRP has more thermal insulation value than and is more thermally and electrically non-conductive than stiffeners made of steel or other metals. Additionally, the FRP stiffeners are corrosion resistant and provide dimensional stability to the panel under thermal loading. The cured-in-place structural combination of the foam and stiffeners eliminates the need to have the stiffeners, in the mid-portions between the ends  52 , otherwise separately adhered to the adjacent sheets  30  to prevent such side-to-side movement. 
     In a method for making the reinforced structural or door panel of the first embodiment ( FIGS. 1-4 ), if stiffeners are to be used the ends  52  of a plurality of the stiffeners  50  are slid tightly into openings  82  of positioning members  80  to lock them in place mechanically. The stiffeners may alternatively be interference fitted or otherwise bonded at their ends  52  to end caps  80 . Polymeric sheets  30  are positioned on each side of stiffeners  50 . The end caps  80  are secured to the upper and lower frame members  90 . Optionally, the stiffeners are secured to frame members  90  directly. If stiffeners are not used, one or more of the polymeric sheet(s)  30  are positioned adjacent one of the panels  40 ,  42 . Whether or not stiffeners are used, bonding material is applied between the polymeric sheets  30  and the adjacent door panels or skins. The opposite ends of upper and lower frame members  90  are attached to side frame members  94  formed by folding side edges of outer panel  42 , and inner panel  40  is secured over and covering the frame members  90 ,  94  and internal stiffeners  50 . The structural members, sheets and door skins or panels may be assembled in any desired sequence. 
     Flowable foam is then injected into any cavities between the inner and outer panels, frame members, stiffeners and polymeric sheets. The injection may be made through foam slot(s)  96  in the frame member(s) at ends or edges of the door shell. If stiffeners are used and the polymeric sheets are of a thickness that provides a gap between the sheet and the stiffener, foam may flow between the sheets and stiffeners to fill substantially all of the cavities making up the interior volume. Where the stiffeners contact the inside surfaces of polymeric sheets, a foam inlet will be provided between each pair of stiffeners, or between a stiffener and the door side frame member. The flowable foam may be a foam material that expands upon contact with the atmospheric air or alternately a two-part foam that expands upon mixing the two parts together. The stiffeners may include openings or slots along the stiffener length which allow the expanding foam to flow from one cavity to an adjacent cavity. The flowable foam then hardens and is bonded to the inside surfaces of the polymeric sheets, frame members, and stiffeners. If foam is to be used to bond the polymeric sheets to the inner and outer panels, then it is pumped into the gaps therebetween in a similar manner. The foam acts both as thermal insulation material and bonds to the door skins or panels, polymeric sheets and stiffeners as an adhesive or direct chemical bond. 
     In a method for making the blast- or ballistic-resistant embodiment of the reinforced door panel ( FIGS. 8-11 ), the polymeric sheets  30   a ,  30   b  are positioned in order with the core blast- or ballistic-resistant material layer(s)  180 . One or more of the polymeric sheet(s)  30   a ,  30   b  are positioned adjacent one or more of the panels  40 ,  42 . Bonding material is applied between the polymeric sheets  30   a ,  30   b  and the adjacent door panels or skins, and optionally between the polymeric sheets  30   a ,  30   b  and the core blast- or ballistic-resistant material layer(s)  180 . The opposite ends of upper and lower frame members  90  are attached to side frame members  94  formed by folding side edges of outer panel  42 , and inner panel  40  is secured over and covering the frame members  90 ,  94  and internal stiffeners  50 . The structural members, sheets and door skins or panels may be assembled in any desired sequence. 
     Instead of using the bonding adhesive, the honeycomb polycarbonate sheets are spaced from the exterior panels  40 ,  42 , and a flowable foam is then injected into cavities therebetween. The injection may be made through foam slot(s)  96  in the frame member(s) at ends or edges of the door shell. The polymeric sheets may also be spaced from the core blast- or ballistic-resistant material layer, and foam injected between. The flowable foam may be a foam material that expands upon contact with the atmospheric air or alternately a two-part foam that expands upon mixing the two parts together. The flowable foam then hardens and is bonded to the inside surfaces of the polymeric sheets, frame members, and stiffeners. The foam acts both as thermal insulation material and bonds to the door skins or panels, polymeric sheets and stiffeners as an adhesive or direct chemical bond. 
     Thus, the present invention provides a door panel in which polymeric sheet(s), with or without structural framework of fiber reinforced polymer, improves the structural integrity and thermal efficiency of the door or other wall panels, and, if without an FRP framework but in combination with blast- or ballistic-resistant material, improves the structural integrity, blast- and ballistic-resistance, and thermal efficiency of the door or other wall panels. 
     In these embodiments, the polycarbonate core can be used in hollow metal, wood, and FRP door designs potentially reducing the number of core types and inventory used in manufacturing. The invention provides major reduction in weight without sacrificing structural strength and blast and ballistic resistance (if employed), is dimensionally stable to reduce thermal bow effect, provides sound transmission class (STC) improvement due to core design and construction, and provides improvement in thermal insulation and air infiltration. The invention provides the option to encapsulate the polycarbonate core with foam in place polyurethane to bond the interior components, polycarbonate core and skins and/or use structural adhesives (epoxy) to bond the polycarbonate core and components to skins. 
     While the present invention has been particularly described, in conjunction with a specific preferred embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations as falling within the true scope and spirit of the present invention.