Stephen M Day

US Patent:

6740381, May 25, 2004

Filed:

Dec 27, 2000

Appl. No.:

09/749064

Inventors:

Stephen W. Day - Dayton OH
Daniel M. Hutcheson - Bellbrook OH
G. Scott Campbell - Dayton OH

Assignee:

Webcore Technologies, Inc. - Centerville OH

International Classification:

B32B 310

US Classification:

428 56, 4283166, 4283099, 4283179, 428 86, 428 74, 4283186, 527821, 527901, 527941

Abstract:

A fiber reinforced core is formed from plastics foam material having elongated porous and fibrous webs and/or rovings extending through the foam material. The rovings may extend angularly through the webs, and strips of the foam material may be helically wound with layers of crossing rovings to form the webs. Porous and fibrous skins for the core may be formed by the wound rovings and by parallel continuous rovings, and the foam strips may be formed with internal grooves adjacent the webs and connected by a feeder channel for infusing a hardenable adhesive resin into the grooves and outwardly through the webs to the skins with differential pressure on the resin.

US Patent:

7393577, Jul 1, 2008

Filed:

Mar 27, 2004

Appl. No.:

10/810298

Inventors:

Stephen W. Day - Dayton OH, US
G. Scott Campbell - Dayton OH, US
Danny E. Tilton - Dayton OH, US
Frederick Stoll - West Chester OH, US
Michael Sheppard - Dayton OH, US
Paul L. Galloway - Clayton OH, US

Assignee:

Webcore Technologies, Inc. - Miamisburg OH

International Classification:

B32B 3/04
B32B 3/26

US Classification:

428121, 4283166, 4283099, 4283179, 428 56, 428 74, 428123, 428126, 428127, 428128, 527821, 527901, 527941

Abstract:

A fiber reinforced core panel is formed from strips of plastics foam helically wound with layers of rovings to form webs which may extend in a wave pattern or may intersect transverse webs. Hollow tubes may replace foam strips. Axial rovings cooperate with overlying helically wound rovings to form a beam or a column. Wound roving patterns may vary along strips for structural efficiency. Wound strips may alternate with spaced strips and spacers between the strips enhance web buckling strength. Continuously wound rovings between spaced strips permit folding to form panels with reinforced edges. Continuously wound strips are helically wrapped to form annular structures, and composite panels may combine both thermoset and thermoplastic resins.

US Patent:

8389104, Mar 5, 2013

Filed:

Sep 30, 2010

Appl. No.:

12/924612

Inventors:

Stephen W. Day - Centerville OH, US
Michael S. Sheppard - Centerville OH, US

Assignee:

Milliken & Company - Spartanburg SC

International Classification:

B32B 33/00
B32B 5/12

US Classification:

428153, 416223 R, 416227 A, 416232

Abstract:

A composite core panel has opposite side surfaces for receiving skins to form a composite sandwich panel. The core panel includes a plurality of spaced blocks of low density cellular material such as foam plastics and have opposite side surfaces forming the side surfaces of the core panel and opposite edge surfaces extending between the side surfaces. A plurality of parallel spaced elongated primary strips of structural cellular material such as balsa wood or engineered foam have a higher density and extend between the blocks, and the blocks have side surfaces adhesively attached to edge surfaces of the blocks. A plurality of parallel spaced secondary strips of structural high density cellular material such as balsa wood or engineered foam extend transversely to the primary strips and have end surfaces adhesively attached to the primary strips and side surfaces adhesively attached to the blocks.

US Patent:

8419883, Apr 16, 2013

Filed:

Nov 8, 2007

Appl. No.:

11/983317

Inventors:

Stephen W. Day - Dayton OH, US
G. Scott Campbell - Dayton OH, US
Danny E. Tilton - Dayton OH, US
Frederick Stoll - West Chester OH, US
Michael Sheppard - Dayton OH, US
Robin Banerjee - Centerville OH, US

Assignee:

Milliken & Company - Spartanburg SC

International Classification:

B29C 65/00
B65H 81/00
B32B 5/14
B32B 7/12

US Classification:

156264, 156169, 156172, 156191, 156195, 1563041, 1563043, 1563045, 1563046, 156428, 156430, 264145, 264148, 264151, 264241, 264257, 264258, 264259, 264263, 264265, 2642711, 264279, 2642791, 264319, 4283099, 4283166, 4283171

Abstract:

A fiber reinforced core panel is formed from strips of plastics foam helically wound with layers of rovings to form webs which may extend in a wave pattern or may intersect transverse webs. Hollow tubes may replace foam strips. Axial rovings cooperate with overlying helically wound rovings to form a beam or a column. Wound roving patterns may vary along strips for structural efficiency. Wound strips may alternate with spaced strips, and spacers between the strips enhance web buckling strength. Continuously wound rovings between spaced strips permit folding to form panels with reinforced edges. Continuously wound strips are helically wrapped to form annular structures, and composite panels may combine both thermoset and thermoplastic resins. Continuously wound strips or strip sections may be continuously fed either longitudinally or laterally into molding apparatus which may receive skin materials to form reinforced composite panels.

US Patent:

8470425, Jun 25, 2013

Filed:

Sep 30, 2010

Appl. No.:

12/924611

Inventors:

Stephen W. Day - Centerville OH, US
Michael S. Sheppard - Centerville OH, US
Frederick Stoll - West Chester OH, US
Danny Tilton - Burnside KY, US

Assignee:

Milliken & Company - Spartanburg SC

International Classification:

B29C 70/86
B32B 3/16
B31B 1/62

US Classification:

428 53, 416223 R, 416227 A, 416232

Abstract:

The plurality of pieces of low density cellular material, such as foam plastics, form a core panel having opposite side surfaces and with adjacent pieces having opposing edge surfaces extending between the side surfaces. Sheets of flexible material, such as veils or mats or scrim, are adhesively attached to the side surfaces, and portions of one sheet extend between the opposing adjacent edge surfaces for limiting flexing of the panel. The pieces may be tapered, and portions of the one sheet may project between the edge surfaces either partially or fully to form double wall webs. The webs may have flanges adhesively attached to the other sheet on the opposite side. One sheet may also be stretchable in areas not adhesively attached to the pieces to provide for curving the panel from a planar position maintained by the sheet on the opposite side.

US Patent:

20120251814, Oct 4, 2012

Filed:

Apr 4, 2011

Appl. No.:

13/066002

Inventors:

Stephen W. Day - Centerville OH, US
Michael S. Sheppard - Centerville OH, US
John P. Jones - Franklin OH, US
Thomas John Ewry - Trotwood OH, US
Danny E. Tilton - Dayton OH, US
Frederick Stoll - West Chester OH, US

International Classification:

B32B 5/14
B65H 81/06
B29C 65/00

US Classification:

4283099, 156204, 156191

Abstract:

A composite core panel is produced by arranging a plurality of foam strips in adjacent relation and advancing the strips with one or two flexible sheets of porous reinforcement material and adhesive between platens to form a panel. The sheet on one side of the strips is folded between adjacent strips to form double wall pleats which may project either partially or fully between the strips and may have folded end portions overlying the other side of the strips. The second sheet may also form double wall pleats between the strips and be connected to the pleats in the first sheet. The core panel may be cut to form reinforced strips which are connected by adhesive in various arrangements to form other core panels. A core panel may also be formed by wrapping each foam strip longitudinally with a strip of reinforcing material and connecting the strips with adhesive.

US Patent:

20130251935, Sep 26, 2013

Filed:

May 21, 2013

Appl. No.:

13/898927

Inventors:

Stephen W. Day - Centerville OH, US
Michael S. Sheppard - Centerville OH, US
Frederick Stoll - West Chester OH, US
Danny Tilton - Burnside KY, US

International Classification:

B32B 3/16
B32B 37/18
E04C 2/38

US Classification:

428 71, 527831, 156300, 428189, 428 98, 428158

Abstract:

The plurality of pieces of low density cellular material, such as foam plastics, form a core panel having opposite side surfaces and with adjacent pieces having opposing edge surfaces extending between the side surfaces. Sheets of flexible material, such as veils or mats or scrim, are adhesively attached to the side surfaces, and portions of one sheet extend between the opposing adjacent edge surfaces for limiting flexing of the panel. The pieces may be tapered, and portions of the one sheet may project between the edge surfaces either partially or fully to form double wall webs. The webs may have flanges adhesively attached to the other sheet on the opposite side. One sheet may also be stretchable in areas not adhesively attached to the pieces to provide for curving the panel from a planar position maintained by the sheet on the opposite side.

US Patent:

20130273308, Oct 17, 2013

Filed:

Mar 25, 2013

Appl. No.:

13/849924

Inventors:

Stephen W. Day - Dayton OH, US
G. Scott Campbell - Dayton OH, US
Danny E. Tilton - Dayton OH, US
Frederick Stoll - Spartanburg SC, US
Michael Sheppard - Centerville OH, US
Robin Banerjee - Centerville OH, US

International Classification:

B32B 5/12
B32B 7/00

US Classification:

428114

Abstract:

A fiber reinforced core panel is formed from strips of plastics foam helically wound with layers of rovings to form webs which may extend in a wave pattern or may intersect transverse webs. Hollow tubes may replace foam strips. Axial rovings cooperate with overlying helically wound rovings to form a beam or a column. Wound roving patterns may vary along strips for structural efficiency. Wound strips may alternate with spaced strips, and spacers between the strips enhance web buckling strength. Continuously wound rovings between spaced strips permit folding to form panels with reinforced edges. Continuously wound strips are helically wrapped to form annular structures, and composite panels may combine both thermoset and thermoplastic resins. Continuously wound strips or strip sections may be continuously fed either longitudinally or laterally into molding apparatus which may receive skin materials to form reinforced composite panels.