Method and apparatus for forming objects having a core and an outer surface structure

Abstract

A method of making at least partially foam-filled sandwich panels includes providing a panel shell, moving at least one of a portion of a first and/or second panel facer or a side member away from the panel volume, thereby defining an opening between the volume and an exterior area. A dispenser proximate the opening moves across at least a portion of the opening while dispensing an amount of a foam agent into the volume through the opening. A press has three platens, a third platen of which is secured to at least one of a portion of the first and/or second facer and the at least one side member and is moveable with respect to the first platen and the second platen in response to a control system.

What is claimed is: 
     
         1 . A press for making a sandwich panel enclosing an amount of foam, comprising:
 a first platen having a generally planar engagement surface;   a second platen having a generally planar engagement surface;   a third platen having a generally planar engagement surface;   a control system;   a frame upon which the first platen, the second platen, and the third platen are disposed, wherein
 the first platen engagement surface opposes the second platen engagement surface, 
 at least one of the first platen and the second platen is movable with respect to the other of the first platen and the second platen on the frame in response to the control system, and 
 the third platen is movable with respect to the first platen and the second platen in response to the control system; and 
   a foam agent dispensing head that is
 in communication with a foam source, 
 movable on the frame over a range of motion in response to the control system, and 
 positioned on the frame so that, upon positioning of the first platen and the second platen so that the first platen engagement surface and the second platen engagement surface oppose and are parallel to each other and define a volume therebetween, and movement of the third platen away from the volume, the foam agent dispensing head is in dispensing communication with the volume. 
   
     
     
         2 . The press as in  claim 1 , wherein the dispensing head comprises a conveyor in engagement with the frame and actuatable by the control system. 
     
     
         3 . The press as in  claim 1 , comprising a negative pressure source in communication with the third platen engagement surface. 
     
     
         4 . The press as in  claim 1 , wherein the third platen is disposed pivotally with respect to the first platen. 
     
     
         5 . The press as in  claim 4 , wherein, in a first position of the third platen, the third platen engagement surface is co-planar with the first platen engagement surface, and in a second position pivoted away from the volume, the first platen engagement surface forms an obtuse angle with respect to the first platen engagement surface. 
     
     
         6 . A press for making a sandwich panel enclosing an amount of foam, comprising:
 a panel shell comprising
 a first generally planar facer, 
 a second generally planar facer generally parallel to and spaced apart from the first facer, and 
 at least one side member extending between the first facer and the second facer so that the first facer, the second facer, and the at least one side member enclose a volume; 
   a first platen having a generally planar engagement surface in engagement with the first facer;   a second platen having a generally planar engagement surface in engagement with the second facer;   a third platen having a generally planar engagement surface in engagement with at least one of
 a portion of at least one of the first facer and the second facer, and 
 the at least one side member; 
   a control system;   a frame upon which the first platen, the second platen, and the third platen are disposed, wherein
 the first platen engagement surface opposes the second platen engagement surface, 
 at least one of the first platen and the second platen is movable with respect to the other of the first platen and the second platen on the frame in response to the control system, and 
 the third platen is secured to the at least one of the portion and the at least one side member and is movable with respect to the first platen and the second platen in response to the control system; and 
   a foam agent dispensing head that is
 in communication with an insulating foam source, 
 movable on the frame over a range of motion in response to the position control system, and 
 positioned on the frame so that, upon movement of the third platen with respect to the first platen and the second platen, so that the third platen moves the at least one of the portion and the at least one side member away from the volume to thereby define an opening between the volume and an area exterior to the panel shell, the foam agent dispensing head is in dispensing communication with the volume via the opening.