Impack Resistant Composite Building Panel

Abstract

A composite building panel that includes a fabric reinforcing sheet between one of the metal skins and the core of the panel. The fabric reinforcing sheet, which is preferably made from aramid fibers improves the impact resistance and penetration resistance of the building panel without substantially increasing weight and without adding fuel content to the panel system.

1 - 16 . (canceled) 
   
   
       17 . A method of manufacturing a building panel comprising:
 an outer metal skin;   an inner metal skin;   a polymer core;   a fabric reinforcing sheet disposed between one of the metal skins and the polymer core;   a first adhesive disposed between the fabric reinforcing sheet and the one of the metal skins, the first adhesive securing the fabric reinforcing sheet to the one of the metal skins;   a second adhesive disposed between the fabric reinforcing sheet and the polymer core, the second adhesive securing the fabric reinforcing sheet to the polymer core; and   a third adhesive disposed between the other of the metal skins and the polymer core, securing the other of the metal skins to the polymer core;   
     the method comprising;
 applying a one side of the fabric reinforcing sheet, having the first adhesive affixed to the one side of the fabric reinforcing sheet and the second adhesive affixed to another side of the fabric reinforcing sheet, to the one of the metal skins; 
 applying the third adhesive to a one side of the other of the metal skins; 
 providing the polymer core; and 
 simultaneously applying the another side of the fabric reinforcing sheet and the one side of the other of the metal skins to the polymer core. 
 
   
   
       18 . The method of  claim 17  wherein the step of applying the one side of the fabric reinforcing sheet includes the step of applying the one side of the fabric reinforcing sheet to the outer metal skin. 
   
   
       19 . The method of  claim 17  wherein the step of applying a one side of the fabric reinforcing sheet to the one of the metal skins comprises the steps of:
 providing an extended length of the one of the metal skins;   heating a portion of the extended length of the one of the metal skins;   providing an extended length of the fabric reinforcing sheet with the first adhesive laminated on the one side of the fabric reinforcing sheet and the second adhesive laminated on the another side of the fabric reinforcing sheet;   pressing a portion of the one side of the fabric reinforcing sheet with the first adhesive laminated on it against a surface of the portion of the extended length of the one of the metal skins; and   heating the portion of the one of the metal skins with the portion of the fabric reinforcing sheet with the first adhesive pressed against it.   
   
   
       20 . The method of  claim 19  wherein the step of applying the third adhesive to a one side of the other of the metal skins comprises the steps of:
 providing an extended length of the other of the metal skins;   heating a portion of the extended length of the other of the metal skins;   providing an extended length of a laminate of the third adhesive;   pressing a portion of the laminate against a surface of the portion of the extended length of the other of the metal skins; and   heating the portion of the extended length of the other of the metal skins with the laminate pressed against it.   
   
   
       21 . The method of  claim 20  wherein the step of simultaneously applying the another side of the portion of the fabric reinforcing sheet with the second adhesive laminated on it and the one side of the other of the metal skins to the polymer core comprises the step of simultaneously pressing the heated combination of the one of the metal skins and the reinforcing fabric sheet with the second adhesive laminated on the another side of the fabric reinforcing sheet and the heated portion of the other of the metal skins with the laminate of the third adhesive pressed against it, respectively each against an opposing side of the polymer core. 
   
   
       22 . The method of  claim 21  wherein the step of simultaneously pressing is achieved by running the heated combination of the portion of the one of the metal skins and the reinforcing fabric sheet with the second adhesive laminated on the another side of the fabric reinforcing sheet, a portion of an extended length of the polymer core and the heated portion of the other of the metal skins with the laminate of the third adhesive pressed against it simultaneously through a pair of rollers. 
   
   
       23 . The method of  claim 22  wherein a predetermined length of the pressed together combination of the one of the metal skins, the fabric reinforcing sheet, the polymer core and the other of the metal skins is periodically cut after it exits the rollers to provide a continuous manufacturing process over at least the shorter of the extended lengths of the reinforcing fabric sheets, the polymer core, the one of the metal skins and the other of the metal skins. 
   
   
       24 . The method of  claim 17  wherein the step of providing the polymer core comprises:
 extruding an extended length of polymer core;   cooling the extruded polymer core; and   reheating the extruded polymer core before simultaneously applying the another side of the fabric reinforcing sheet and the one side of the other of the metal skins to the polymer core.   
   
   
       25 . The method of  claim 24  wherein the cooling step comprises air cooling. 
   
   
       26 . The method of  claim 17  including the step of making the fabric reinforcing sheet from aramid fibers.