Process for producing panels

Abstract

A process for forming a panel 10, such as structural panels, such as raised flooring panels, or vehicle body panels, the panel comprises an outer casing 12 formed of metal or fibre reinforced composite material and encasing a core material 14 comprising a heat activated foamable material mixed with a particulate material, the process comprises the steps of forming a hollow casing comprising at least one fill opening 20, filling the hollow casing with the core material through the fill opening, closing the fill opening, heating the panel in a mould (24, fig 3) defining an enclosed mould chamber (34) to activate and expand the foamable material to fill the casing and cooling the panel before opening of the mould. The particulate material may include recycled plastic or chopped mixed waste material. The casing may be formed with at least one vent opening, and the mould and the open casing may be pre-heated prior to the steps of filling and closing the casing and closing the mould.

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