Durakon Industries, Inc.

Zbigniew Roman Pedzinski

John C Montagna

Leslie E Smith

A composite material includes five distinct layers of material: two thin outer layers or panels, a central rigid core and intermediate foam layers on both sides of the core which fill the regions between the core and outer panels. The core can be a wide variety of material but is preferably a rigid foam or wood having resin or epoxy impregnated fiber or fiber filled outer skins. An array of apertures extends through the core. During the fabrication process, the apertures facilitate cross flow of the foam and ensure even distribution thereof. As a finished product, the foam filled apertures ensure positive location and retention of the core within the foam. The foam may be any suitable injectable foam but is preferably a composition which remains resilient upon curing as such foam more readily accommodates dimensional changes between the layers due to, for example, ambient temperatures changes. The core and foam are surrounded with top and bottom panels of a moldable thermoplastic material such as high density polyethylene (HDPE) which is capable of being molded with a high quality exterior finish.

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Sarnia, Canada

Zbigniew Roman Pedzinski