초록 ▼

A mass transit flooring assembly including a plurality of sandwich panels. The sandwich panels ( 30 ) include a top skin ( 54 ), a bottom skin ( 58 ), a perimeter defining closeout ( 46 ), and a core ( 50 ) between the top ( 54 ) and bottom skin ( 58 ) and within the closeout parameter ( 46 ). The c

A mass transit flooring assembly including a plurality of sandwich panels. The sandwich panels ( 30 ) include a top skin ( 54 ), a bottom skin ( 58 ), a perimeter defining closeout ( 46 ), and a core ( 50 ) between the top ( 54 ) and bottom skin ( 58 ) and within the closeout parameter ( 46 ). The closeout ( 46 ) includes mating surfaces used to connect adjacent panels. The core is a precured reinforced core including a plurality of phenolic ribs and foam strips positioned in an alternating fashion. The precured core is manufactured by impregnating a layer of fabric with phenolic resin between two foam cores and stacking in a similar alternating fashion to create a bun. After the bun is cured at a constant pressure and temperature and cooled, the bun is cut along a plane perpendicular to the plane of the layers to provide a precured reinforced core panel ready to be inserted as a core in a sandwich panel.

대표청구항 ▼

1. A panel comprising:a top skin having a thickness;a bottom skin having a thickness;a core located between the top and bottom skins; andcloseout contacting the top skin and the bottom skin, wherein the closeout surrounds the core and substantially defines the perimeter of the panel, the closeout be

1. A panel comprising:a top skin having a thickness;a bottom skin having a thickness;a core located between the top and bottom skins; andcloseout contacting the top skin and the bottom skin, wherein the closeout surrounds the core and substantially defines the perimeter of the panel, the closeout being a fiber reinforced material having a thickness that is substantially greater than the thickness of the top skin and the thickness of the bottom skin, wherein the top skin, the bottom skin, and closeout are a phenolic composite. 2. A panel as claimed in claim 1, wherein the core is a precured reinforced core. 3. A panel as claimed in claim 2, wherein the precured reinforced core includes at least one phenolic rib and a plurality of foam strips, the phenolic rib being positioned between two foam strips. 4. A panel as claimed in claim 1, wherein the closeout is machinable to include at least one mating surface. 5. A panel as claimed in claim 4, wherein the mating surface is a lap joint. 6. A panel as claimed in claim 4, wherein the panel defines a plane, the closeout being machinable to include at least one bore through the closeout, the bore being perpendicular to the plane. 7. A panel as claimed in claim 1, wherein the core further includes at least one tapping block, the tapping block including a fiber reinforced material block and a metal plate encapsulated within the block, the tapping block adapted to be drilled and tapped so as to provide the panel with a mounting area with increased support. 8. A panel as claimed in claim 1, wherein the core further includes at least one mounting block, the mounting block including a fiber reinforced material block and being adapted to be drilled so as to provide the panel with a mounting area with increased support. 9. A flooring assembly comprising:a plurality of panels, said panels being interconnected and each panel of said plurality of panels includinga top skin having a thickness,a bottom skin having a thickness,a core located between the top and bottom skins; andcloseout between the top skin and the bottom skin wherein the closeout surrounds the core and substantially defines the perimeter of the panel, the closeout being a fiber reinforced material having a thickness that is substantially greater than the thickness of the top skin and the thickness of the bottom skin, wherein the top skin, the bottom skin, and closeout are a phenolic composite. 10. A flooring assembly as claimed in claim 9, wherein the core is a precured reinforced core. 11. A flooring assembly as claimed in claim 10, wherein the precured reinforced core includes at least one phenolic rib and a plurality of foam strips, the phenolic rib being positioned between two foam strips. 12. A flooring assembly as claimed in claim 9, wherein the closeout is machinable to include at least one mating surface. 13. A flooring assembly as claimed in claim 12, wherein the mating surface is a lap joint. 14. A flooring assembly as claimed in claim 12, wherein the panel defines a plane, the closeout being machinable to include at least one bore through the closeout, the bore being perpendicular to the plane. 15. A flooring assembly as claimed in claim 9, wherein the core further includes at least one tapping block, the tapping block including a fiber reinforced material block and a metal plate encapsulated within the block, the tapping block adapted to be drilled and tapped so as to provide the panel with a mounting area with increased support. 16. A flooring assembly as claimed in claim 9, wherein the core further includes at least one mounting block, the mounting block including a fiber reinforced material block and being adapted to be drilled so as to provide the panel with a mounting area with increased support. 17. A flooring assembly for use in mass transit vehicles, wherein the mass transit vehicle includes a car assembly including spaced apart side walls, spaced apart end walls, and a floor support assembly, said composite fl ooring assembly comprising:a plurality of panels interconnected to cover the floor support assembly, and each panel of said plurality of panels includinga top skin having a thickness,a bottom skin having a thickness,a core located between the top and bottom skins; andcloseout between the top skin and the bottom skin wherein the closeout surrounds the core and substantially defines the perimeter of the panel, the closeout being a fiber reinforced material having a thickness that is substantially greater than the thickness of the top skin and the thickness of the bottom skin, wherein the core is a precured reinforced core, and wherein the precured reinforced core includes at least one phenolic rib and a plurality of foam strips, the phenolic rib being positioned between two foam strips. 18. A flooring assembly as claimed in claim 17, wherein the closeout is machinable to include at least one mating surface. 19. A flooring assembly as claimed in claim 18, wherein the mating surface is a lap joint. 20. A flooring assembly as claimed in claim 18, wherein the panel defines a plane, the closeout being machinable to include at least one bore through the closeout, the bore being perpendicular to the plane. 21. A flooring assembly as claimed in claim 17, wherein the core further includes at least one tapping block, the tapping block including a fiber reinforced material block and a metal plate encapsulated within the block, the tapping block adapted to be drilled and tapped so as to provide the panel with a mounting area with increased support. 22. A flooring assembly as claimed in claim 17, wherein the core further includes at least one mounting block, the mounting block including a fiber reinforced material block and being adapted to be drilled so as to provide the panel with a mounting area with increased support. 23. A method of manufacturing precured reinforced core, said method comprising the steps of:providing a foam core to act as a base;placing at least one layer of fabric on top of the foam core base;fully impregnating each layer of fabric with phenolic resin;placing a top layer of foam core on the impregnated fabric to create a bun;curing the bun at a requisite temperature and pressure; andcooling the bun thereby creating a finished laminate between the foam layers of the bun such that the laminate does not allow any additional resin to penetrate between the foam layers. 24. A method of manufacturing as claimed in claim 23, further comprising the steps of:placing at least one intermediate layer of foam core on top of the impregnated fabric;placing at least one layer of fabric on top of the foam core intermediate; andimpregnating each layer of fabric with phenolic resin. 25. A method of manufacturing as claimed in claims 23 , further comprising the steps of:cutting the bun along a plane perpendicular to the plane of the cores to provide a panel of precured reinforced core. 26. A method of manufacturing as claimed in claim 23, wherein the foam core is a rigid closed-cell foam. 27. A method of manufacturing as claimed in claim 23, wherein the fabric is fiberglass fabric. 28. A method of manufacturing as claimed in claim 27, wherein the fiberglass fabric is bi-axially-oriented. 29. A method of manufacturing as claimed in claim 23, wherein the temperature is constant. 30. A method of manufacturing as claimed in claim 29, wherein the constant temperature is between 160 and 180 degrees Fahrenheit. 31. A method of manufacturing as claimed in claim 23, wherein the pressure is constant. 32. A method of manufacturing as claimed in claim 31, wherein the pressure is between 25 and 40 psi. 33. A panel comprising:a top skin;a bottom skin; anda precured reinforced core made by a method including the steps ofproviding a foam core to act as a base,placing at least one layer of fabric on top of the foam core base,fully impregnating each layer of fabric with phenolic resin,placing a top layer of foam core on the impregnated fabric to create a bu n,curing the bun at a requisite temperature and pressure, andcooling the bun thereby creating a finished laminate between the foam layers of the bun such that the laminate does not allow any additional resin to penetrate between the foam layers. 34. The panel of claim 33, wherein the method of making the precured reinforced core further includes the steps of:placing at least one intermediate layer of foam core on top of the impregnated fabric;placing at least one layer of fabric on top of the foam core intermediate; andimpregnating each layer of fabric with phenolic resin. 35. The panel of claim 33, wherein the method of making the precured reinforced core further includes the steps of:cutting the bun along a plane perpendicular to the plane of the cores to provide a panel of precured reinforced core. 36. The panel of claim 33, wherein the foam core is a rigid closed-cell foam. 37. The panel of claim 33, wherein the fabric is fiberglass fabric. 38. The panel of claim 37, wherein the fiberglass fabric is bi-axially-oriented. 39. The panel of claim 33, wherein the temperature is constant. 40. The panel of claim 39, wherein the constant temperature is between 160 and 180 degrees Fahrenheit. 41. The panel of claim 33, wherein the pressure is constant. 42. The panel of claim 41, wherein the pressure is between 25 and 40 psi. 43. A panel comprising:a top skin;a bottom skin;a core located between the top and bottom skins, wherein the core includes at least one tapping block, the tapping block includinga fiber reinforced material block anda metal plate encapsulated within the block, wherein the tapping block is adapted to be drilled and tapped so as to provide the panel with a mounting area with increased support. 44. A panel as claimed in claim 1, wherein the top skin and bottom skin are separated by a distance, the thickness of the closeout being greater than the distance between the top skin and bottom skin. 45. A panel as claimed in claim 1, wherein the closeout is made from a material that is capable of passing flame and smoke tests for the mass transit industry. 46. A panel as claimed in claim 1, wherein the closeout is made from a water resilient material. 47. A panel comprising:a top skin having a thickness;a bottom skin having a thickness;a core located between the top and bottom skins; andcloseout contacting the top skin and the bottom skin, wherein the closeout surrounds the core and substantially defines the perimeter of the panel, the closeout being a fiber reinforced material having a thickness that is substantially greater than the thickness of the top skin and the thickness of the bottom skin, wherein the core is a precured reinforced core, and wherein the precured reinforced core includes at least one phenolic rib and a plurality of foam strips, the phenolic rib being positioned between two foam strips. 48. A panel comprising:a top skin having a thickness;a bottom skin having a thickness;a core located between the top and bottom skins; andcloseout contacting the top skin and the bottom skin, wherein the closeout surrounds the core and substantially defines the perimeter of the panel, the closeout being a fiber reinforced material having a thickness that is substantially greater than the thickness of the top skin and the thickness of the bottom skin, wherein the core further includes at least one mounting block, the mounting block including a fiber reinforced material block and being adapted to be drilled so as to provide the panel with a mounting area with increased support. 49. A flooring assembly comprising:a plurality of panels, said panels being interconnected and each panel of said plurality of panels includinga top skin having a thickness,a bottom skin having a thickness,a core located between the top and bottom skins; andcloseout between the top skin and the bottom skin wherein the closeout surrounds the core and substantially defines the perimeter of the panel, the closeout being a fiber reinforced material ha ving a thickness that is substantially greater than the thickness of the top skin and the thickness of the bottom skin, wherein the core is a precured reinforced core, and wherein the precured reinforced core includes at least one phenolic rib and a plurality of foam strips, the phenolic rib being positioned between two foam strips. 50. A flooring assembly comprising:a plurality of panels, said panels being interconnected and each panel of said plurality of panels includinga top skin having a thickness,a bottom skin having a thickness,a core located between the top and bottom skins; andcloseout between the top skin and the bottom skin wherein the closeout surrounds the core and substantially defines the perimeter of the panel, the closeout being a fiber reinforced material having a thickness that is substantially greater than the thickness of the top skin and the thickness of the bottom skin, wherein the core further includes at least one mounting block, the mounting block including a fiber reinforced material block and being adapted to be drilled so as to provide the panel with a mounting area with increased support. 51. A flooring assembly for use in mass transit vehicles, wherein the mass transit vehicle includes a car assembly including spaced apart side walls, spaced apart end walls, and a floor support assembly, said composite flooring assembly comprising:a plurality of panels interconnected to cover the floor support assembly, and each panel of said plurality of panels includinga top skin having a thickness,a bottom skin having a thickness,a core located between the top and bottom skins; andcloseout between the top skin and the bottom skin wherein the closeout surrounds the core and substantially defines the perimeter of the panel, the closeout being a fiber reinforced material having a thickness that is substantially greater than the thickness of the top skin and the thickness of the bottom skin, wherein the core further includes at least one mounting block, the mounting block including a fiber reinforced material block and being adapted to be drilled so as to provide the panel with a mounting area with increased support.