Composite Panel Having Perforated Foam Core

Abstract

A composite panel configured for use with a sidewall of a trailer includes an outer metal sheet, an inner metal sheet, and a core member positioned between the inner and outer metal sheets. The core member includes a plurality of apertures formed therethrough such that each aperture extends from an inner surface of the core member to an outer surface of the core member. Illustratively, the plurality of apertures is covered by the inner and outer metal sheets.

What is claimed is: 
     
         1 . A composite panel configured for use with a sidewall of a trailer comprising:
 an outer metal sheet;   an inner metal sheet; and   a core member positioned between the inner and outer metal sheets, wherein the core member includes a plurality of apertures formed therethrough such that each aperture extends from an inner surface of the core member to an outer surface of the core member, wherein the plurality of apertures is covered by the inner and outer metal sheets, and wherein a length and width of each aperture is less than a respective length and width of the core member.   
     
     
         2 . The composite panel of  claim 1 , wherein the plurality of apertures are circular in shape. 
     
     
         3 . The composite panel of  claim 2 , wherein a diameter of each aperture is in the range of approximately ¼ inch to ½ inch. 
     
     
         4 . The composite panel of  claim 1 , further comprising an adhesive between the inner metal sheet and the core member and between the outer metal sheet and the core member. 
     
     
         5 . The composite panel of  claim 1 , wherein the plurality of apertures includes a plurality of adjacent vertical rows of apertures that are aligned with each other and a plurality of adjacent horizontal rows of apertures that are aligned with each other. 
     
     
         6 . The composite panel of  claim 1 , wherein the plurality of apertures includes a plurality of adjacent vertical rows of apertures that are offset from each other and a plurality of adjacent horizontal rows of apertures that are offset from each other. 
     
     
         7 . The composite panel of  claim 1 , wherein a top-most horizontal row of apertures is spaced-apart from a top edge of the core member. 
     
     
         8 . The composite panel of  claim 7 , wherein a vertical distance between the top edge of the core member and a center of the top-most horizontal row of apertures is between approximately 0.50-6.00 inches. 
     
     
         9 . The composite panel of  claim 8 , wherein the vertical distance is approximately 2.0 inches. 
     
     
         10 . The composite panel of  claim 1 , wherein a left-most vertical row of apertures is spaced-apart from a left side edge of the core member. 
     
     
         11 . The composite panel of  claim 10 , wherein a horizontal distance between the left side edge of the core member and a center of the left-most vertical row of apertures is between approximately 0.50-6.00 inches. 
     
     
         12 . The composite panel of  claim 11 , wherein the horizontal distance is approximately 6.0 inches. 
     
     
         13 . The composite panel of  claim 1 , wherein a top-most horizontal row of apertures is spaced-apart a first distance from a top edge of the core member, wherein a left-most vertical row of apertures is spaced-apart a second distance from a left side edge of the core member, and wherein the first distance is smaller than the second distance. 
     
     
         14 . The composite panel of  claim 1 , wherein the apertures are generally uniformly spaced-apart from one another. 
     
     
         15 . The composite panel of  claim 1 , wherein the apertures are generally similarly-sized. 
     
     
         16 . The composite panel of  claim 1 , wherein the core member is a foamed core member including a plurality of air bubbles therein. 
     
     
         17 . The composite panel of  claim 1 , wherein none of the plurality of apertures is open to any one of a top, bottom, or side edge of the core member. 
     
     
         18 . The composite panel of  claim 1 , wherein the plurality of apertures includes a plurality of vertically-spaced apart apertures and a plurality of horizontally spaced-apart apertures. 
     
     
         19 . A sidewall of a trailer comprising
 a first composite panel including (i) a first outer metal sheet, (ii) a first inner metal sheet, and (iii) a first core member positioned between the first inner and first outer metal sheets, wherein the first core member includes a first plurality of apertures which are both vertically and horizontally spaced-apart from each other, wherein each of the first plurality of apertures extends from an inner surface of the first core member to an outer surface of the first core member, wherein the first plurality of apertures is covered by the first inner and first outer metal sheets, wherein the first core member includes a first aperture-free side portion;   a second composite panel including (i) a second outer metal sheet, (ii) a second inner metal sheet, and (iii) a second core member positioned between the second inner and second outer metal sheets, wherein the second core member includes a second plurality of apertures which are both vertically and horizontally spaced-apart from each other, wherein each of the second plurality of apertures extends from an inner surface of the second core member to an outer surface of the second core member, wherein the second plurality of apertures is covered by the second inner and second outer metal sheets, wherein the second core member includes a second aperture-free side portion; and   a wall joint coupling the first and second composite panels to each other, the wall joint including a plurality of fasteners received through the first and second aperture-free portions of the first and second composite panels.   
     
     
         20 . A method of forming a composite panel configured for use in a sidewall of a trailer, the method comprising:
 forming an uncooled thermal plastic sheet of material;   advancing the uncooled thermal plastic sheet of material through a transversing punch in order to form apertures through the uncooled thermal plastic sheet of material such that each aperture extends from an outer surface of the thermal plastic sheet of material to an inner surface of the thermal plastic sheet of material;   cooling the transversing punch; and   coupling an outer metal sheet and an inner metal sheet to the respective outer surface and the inner surface of the uncooled thermal plastic sheet of material.