Composite model construction and method

Abstract

The composite model construction uses a semi-flexible expanded polypropylene foam plastic core with a thin, semi-rigid polycarbonate plastic shell adhesively attached to the core. The core includes various rigid structural members installed therein, as required, for sufficient structural stiffness for the model. The core and plastic shell components may be formed by injection molding, vacuum forming, or other processes. The model construction method provides a highly accurate outer surface for a model, with the outer shell being formed with scale details, such as panel seams, rivet lines, etc. during the molding or forming process. A motor or other prime mover may be added to the composite model body. The materials used in the composite model are resilient with a flexible yet tough outer shell to resist impact damage, and allow repairs to be made quickly and easily when required.

1 . A miniature vehicle body, comprising: 
 at least one resilient foam plastic core member; and    at least one thin, single ply, semi-rigid plastic outer shell member having at least an outer surface and a shape closely conforming to said core member, the outer shell member being adhesively joined to and covering said core member, said core member and said outer shell member forming the miniature vehicle body.    
   
   
       2 . The miniature vehicle body according to  claim 1 , wherein said at least one core member has at least one rigid structural reinforcement member cavity formed therein, the miniature vehicle further comprising a rigid structural reinforcement member installed and fitting closely within the at least one cavity of said at least one core member.  
   
   
       3 . The miniature vehicle body according to  claim 1 , wherein said at least one core member has at least one remote control system compartment formed therein.  
   
   
       4 . The miniature vehicle body according to  claim 1 , wherein said at least one core member comprises a plurality of core members and said at least one outer shell member comprises a plurality of outer shell members.  
   
   
       5 . The miniature vehicle body according to  claim 1 , wherein said outer shell member has simulated structural scale detailing formed upon the outer surface integrally therewith.  
   
   
       6 . The miniature vehicle body according to  claim 1 , wherein said at least one core member is formed of expanded polypropylene foam plastic.  
   
   
       7 . The miniature vehicle body according to  claim 1 , wherein said at least one outer shell member is formed of polycarbonate plastic.  
   
   
       8 . A kit for a miniature vehicle, comprising: 
 at least one resilient foam plastic core member; and    at least one preformed, thin, single ply, semi-rigid plastic outer shell member, adapted to fit closely about said at least one foam plastic core member.    
   
   
       9 . The kit for a miniature vehicle according to  claim 8 , wherein said core member has at least one structural member cavity formed therein, the kit further comprising a rigid structural reinforcement member dimensioned and configured for at least partial insertion into the cavity.  
   
   
       10 . The kit for a miniature vehicle according to  claim 8 , wherein said at least one core member has at least one remote control system compartment formed therein.  
   
   
       11 . The kit for a miniature vehicle according to  claim 8 , wherein said at least one core member comprises a plurality of core members and said at least one outer shell member comprises a plurality of outer shell members.  
   
   
       12 . The kit for a miniature vehicle according to  claim 8 , wherein said outer shell member has simulated structural scale detailing formed upon the outer surface integrally therewith.  
   
   
       13 . The kit for a miniature vehicle according to  claim 8 , wherein said at least one core member is formed of expanded polypropylene foam plastic.  
   
   
       14 . The kit for a miniature vehicle according to  claim 8 , wherein said at least one outer shell member is formed of polycarbonate plastic.  
   
   
       15 . A method of manufacturing a kit for a miniature vehicle, comprising the steps of: 
 (a) forming a plurality of resilient foam plastic core members, the core members;    (b) forming a plurality of thin, single ply, semi-rigid plastic shell members having a shape closely conforming to at least one of the core members; and    (c) packaging the at least one core member and the at least one shell member together for later assembly.    
   
   
       16 . The method of manufacturing a kit according to  claim 15 , further including the steps of: 
 (a) forming complementary rigid structural reinforcement member cavities within at least two core members; and    (b) forming at least one rigid structural reinforcement member conforming to the complementary cavities for later joining of the core members.    
   
   
       17 . The method of manufacturing a kit according to  claim 15 , wherein step (a) further comprises forming said core members by injection molding.  
   
   
       18 . The method of manufacturing a kit according to  claim 15 , wherein said step of forming the outer shell members further comprises forming the outer shell members by vacuum forming.  
   
   
       19 . The method of manufacturing a kit according to  claim 18 , wherein said the step of vacuum forming the outer shell members includes providing a mold for shaping simulated structural scale details upon the outer surface of the outer shell members.  
   
   
       20 . The method of manufacturing a kit according to  claim 15 , wherein said step of forming the outer shell members includes forming a joggle on adjacent outer shell members for later assembly of joggle lap joints.