Method for forming a cellular core member

• Main Authors: COURT MELVIN T, COURT CALVIN LANCE, COURT CALVIN LEROY
• Format: Patent
• Language: English
• Published: 14.01.2003
• Edition: 7
• Subjects: BUILDING; BUILDING MATERIALS; FIXED CONSTRUCTIONS; STRUCTURAL ELEMENTS

A plurality of thermoplastic tubular segments having substantially equal lengths are arranged in horizontal side-by-side relationship with the respective ends of the tubular segments aligned in a generally common plane. Small portions of the respective ends of the tubes are cut by a thermal cutting device which simultaneously fuses the ends of the tubes to produce a consolidated unitary structure having a thickness defined by the distance between the fused ends of the tubular segments. The consolidated unitary structure is then rotated to a horizontal position, with the tubular segments vertically oriented, and cut along at least one horizontal plane to produce fused cores having a thickness defined by the vertical position of a horizontally disposed thermal cutting device. Cutting consolidated unitary structures of thermoplastic tubular segments along horizontal planes, while the consolidated unitary structure is disposed horizontally, avoids the manufacturing and material handling problems previously associated with vertical cutting of consolidated unitary structures.