U.S. patent application number 13/318771 was filed with the patent office on 2012-03-01 for structured-core laminate panels and methods of forming the same.
This patent application is currently assigned to 3FORM, INC.. Invention is credited to M. Hoyt Brewster, Charles H. Moore, John E.C. Willham.
Application Number | 20120048487 13/318771 |
Document ID | / |
Family ID | 43085530 |
Filed Date | 2012-03-01 |
United States Patent
Application |
20120048487 |
Kind Code |
A1 |
Brewster; M. Hoyt ; et
al. |
March 1, 2012 |
STRUCTURED-CORE LAMINATE PANELS AND METHODS OF FORMING THE SAME
Abstract
A structured-core laminate panel can be made in an efficient,
structurally sound manner without the use of adhesives (film or
liquid forms) using materials with different melt or glass
transition temperatures. In one implementation, a manufacturer
positions one or more resin substrates about a structured core,
which comprises a relatively high melt or glass transition
temperature compared with that of the one or more resin substrates.
The manufacturer heats the assembly to at least the glass
transition temperature of the resin substrates, but not to the melt
or glass transition temperature of the structured core. This allows
the one or more resin substrates to melt and bond (mechanically,
chemically, or both) to the structured core on one side (or inner
surface), while maintaining a substantially planar or original
conformation on an opposing side (or outer surface).
Inventors: |
Brewster; M. Hoyt; (Salt
Lake City, UT) ; Moore; Charles H.; (Salt Lake City,
UT) ; Willham; John E.C.; (Sandy, UT) |
Assignee: |
3FORM, INC.
Salt Lake City
UT
|
Family ID: |
43085530 |
Appl. No.: |
13/318771 |
Filed: |
May 11, 2010 |
PCT Filed: |
May 11, 2010 |
PCT NO: |
PCT/US10/34349 |
371 Date: |
November 3, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61177939 |
May 13, 2009 |
|
|
|
Current U.S.
Class: |
160/368.1 ;
264/248; 428/116 |
Current CPC
Class: |
B32B 37/12 20130101;
B32B 2250/24 20130101; B32B 2307/4026 20130101; B32B 2419/06
20130101; B32B 23/08 20130101; B32B 27/365 20130101; B32B 2307/50
20130101; B32B 2419/04 20130101; B32B 37/04 20130101; E04C 2/36
20130101; Y10T 428/24942 20150115; B32B 27/06 20130101; B32B 27/40
20130101; B32B 2307/30 20130101; E04F 10/00 20130101; B29D 24/005
20130101; B32B 27/08 20130101; B32B 2471/00 20130101; Y10T
428/24157 20150115; E04C 2/20 20130101; B32B 27/36 20130101; B32B
2307/558 20130101; E04B 9/32 20130101; B32B 23/20 20130101; E04B
9/045 20130101; E04C 2/24 20130101; Y10T 428/24149 20150115; B32B
2451/00 20130101; B32B 2607/00 20130101; E04C 2/54 20130101; B32B
2307/414 20130101; B32B 27/32 20130101; E06B 5/00 20130101; B32B
3/12 20130101; B32B 27/308 20130101; B32B 27/20 20130101; B32B 7/02
20130101; B32B 27/302 20130101 |
Class at
Publication: |
160/368.1 ;
264/248; 428/116 |
International
Class: |
E04C 2/54 20060101
E04C002/54; B32B 3/12 20060101 B32B003/12; B29C 65/02 20060101
B29C065/02 |
Claims
1. A method of manufacturing a translucent, structured-core
laminate panel in a manner that substantially resists delamination,
and without use of an adhesive film, comprising: preparing a
laminate assembly comprising one or more resin substrates having a
first glass transition temperature positioned about a structured
core having a second melt or glass transition temperature, wherein
the first glass transition temperature is lower than the second
melt or glass transition temperature; heating the laminate assembly
to a processing temperature at least as great as the first glass
transition temperature but below the second melt or glass
transition temperature, wherein a portion of the one or more resin
substrates flows into the structured core; and cooling the laminate
assembly below the first glass transition temperature to create a
unitary structured-core laminate panel; wherein the one or more
resin substrates bond to the structured core without substantial
deformation of the structured core.
2. The method as recited in claim 1, wherein the processing
temperature is between about 180.degree. F. and about 275.degree.
F., and the method further comprises subjecting the laminate
assembly to a processing pressure of about 40 psi.
3. The method as recited in claim 1, wherein: the structured-core
comprises a honeycomb matrix with a plurality of structured
chambers made substantially of polycarbonate or mixtures thereof,
and the one or more resin substrates comprise a sheet of
copolyester, acrylic, or mixtures thereof.
4. The method as recited in claim 1, further comprising positioning
a colored film against at least one of the one or more resin
substrates.
5. The method as recited in claim 4, further comprising positioning
an additional resin substrate against the colored film opposite the
at least one of the one or more resin substrates.
6. The method as recited in claim 4, wherein each of the one or
more resin substrates, the structured core, and color film are
thermoformed together in a single step.
7. The method as recited in claim 1, further comprising positioning
the laminate assembly into a vacuum bag, wherein the laminate
assembly is heated and/or pressurized in a vacuum press or
autoclave.
8. The method as recited in claim 1, wherein the structured core
comprises a plurality of cylinder-shaped cells having openings at a
first end and an opposing second end.
9. The method as recited in claim 8, further comprising:
positioning a first surface of a first translucent resin substrate
and a second surface of a second translucent resin substrate in
substantially perpendicular orientations relative to the
cylinder-shaped cells; wherein the first surface covers the
openings of the first end of the plurality cylinder-shaped cells,
and the second surface covers the openings of the second end of the
plurality cylinder-shaped cells.
10. A structured-core laminate panel prepared in accordance with
the process recited in claim 1.
11. A structured-core laminate panel with sufficient structural
properties for use as a building component, comprising: at least
one resin substrate having a first glass transition temperature;
and at least one structured-core positioned directly against a
first surface of the at least one resin substrate, the at least one
structured-core comprising a plurality of cells; wherein: the at
least one structured core has a second melt or glass transition
temperature that is higher than the first glass transition
temperature, and a portion of the at least one resin substrate
positioned directly against the at least one structured core is
fused to and within the plurality of cells of the at least one
structured core.
12. The structured-core laminate panel as recited in claim 11,
further comprising a colored film fused to a second surface of the
at least one resin substrate opposite the first surface.
13. The structured-core laminate panel as recited in claim 12,
further comprising: an additional resin substrate fused to the
colored film; wherein the colored film is positioned between the at
least one substrate and the additional substrate.
14. The structured-core laminate panel as recited in claim 11,
wherein the at least one structured-core comprises polycarbonate
and the at least one resin substrate comprises a translucent
copolyester.
15. The structured-core laminate panel as recited in claim 11,
wherein the plurality of cells of the at least one structured-core
comprise honeycomb cells.
16. The structured-core laminate panel as recited in claim 11,
wherein the plurality of cells of the at least one structured-core
comprise cylindrical-shaped cells oriented perpendicularly to the
first surface of the at least one resin substrate.
17. The structured-core laminate panel as recited in claim 11,
wherein the plurality of cells comprise cells having at least three
different sizes.
18. A panel system configured for use as a partition that provides
both light transmission and privacy, comprising: one or more
translucent structured-core laminate panels, comprising: one or
more resin substrates having a first glass transition temperature,
and one or more structured cores including a plurality of cells,
the one or more structured cores having a second melt or glass
transition temperature that is greater than the first glass
transition temperature, wherein a portion of the one or more resin
substrates extend into and are fused to the plurality of cells of
the one or more structured cores; and a mounting system that
secures to the one or more translucent structured-core laminate
panels to a support structure.
19. The panel system as recited in claim 18, wherein the mounting
system comprises hardware that supports the one or more translucent
structured-core laminate panels as a sliding door.
20. The panel system as recited in claim 18, wherein the mounting
system comprises hardware that supports the one or more translucent
structured-core laminate panels as one or more of a ceiling, floor,
wall, or partition.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present invention is a national stage of PCT/US10/34349,
filed May 11, 2010, entitled "Structured-Core Laminate Panels and
Methods of Forming the Same," which claims the benefit of priority
to U.S. Provisional Application No. 61/177,939, filed May 13, 2009,
entitled "Laminated Structured-Core Panels." The entire content of
each of the aforementioned patent applications is incorporated by
reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. The Field of the Invention This invention relates to
apparatus, systems, and methods for panels that can be used as a
ceiling, wall, or floor structure, or as a treatment thereto.
[0003] 2. Background and Relevant Art
[0004] Recent trends in building design involve using one or more
sets of decorative panels to add to the functional and/or aesthetic
characteristics of a given structure or design space. These recent
trends are due, at least in part, because there is sometimes more
flexibility with how the given panel (or set of panels) is
designed, compared with the original structure. For example, recent
panel materials include synthetic, polymeric resin materials, which
can be formed as panels to be used as partitions, walls, barriers,
treatments, decor, etc. Examples of such resin materials include
polyvinyl chloride or "PVC"; polyacrylate materials such as poly
(methyl methacrylate) or "PMMA"; polyester materials such as poly
(ethylene-co-cyclohexane 1,4-dimethanol terephthalate), or "PET";
poly (ethylene-co-cyclohexane 1,4-dimethanol terephthalate glycol)
or "PETG"; glycol modified polycyclohexylenedimethlene
terephthalate; or "PCTG"; as well as polycarbonate (or "PC")
materials.
[0005] In general, resin materials such as these are now popular
compared with decorative cast or laminated glass materials, since
resin materials may be manufactured to be more resilient and to
have a similar transparent, translucent, or decorative appearance
as cast or laminated glass, but with less cost. Decorative resins
can also provide more flexibility compared with glass at least in
terms of color, degree of texture, gauge, impact resistance, and
ease of fabrication.
[0006] One particular type of resin panel that is now popular is
honeycomb core panels. Honeycomb core panels include a honeycomb
core bonded between two outer sheets or skins. Such panels are
popular because the core reduces the overall weight of the panel,
while also increasing the strength of the panel. Furthermore, the
honeycomb core can provide a unique aesthetic.
[0007] One conventional mechanism for creating honeycomb core
laminate panels can involve adhering a honeycomb core between two
substrates with an adhesive. The adhesive may be liquid at the time
of application, which allows the honeycomb core and substrates to
bond together with relative immediacy. To apply the adhesive, the
manufacturer may spread (e.g., with one or more rollers) or spray a
liquid adhesive on both sides of a honeycomb core or to a single
side of one or more substrate panels, or skins, and then press such
panels directly against the honeycomb core. Such liquid
laminations, however, may be relatively weak in the context of
building materials. In particular, such liquid laminations can have
a greater risk of delamination since the bond strength can be
primarily determined by uniformity of the liquid adhesive
application, which is susceptible to bubbles, voids, debris, and
relies on chemical bonding.
[0008] In other cases, a manufacturer can utilize a solid resin
film adhesive. For example, the manufacturer first adheres,
laminates, or attaches a solid adhesive resin film on one side of
one or more substrate panels. The manufacturer then performs a
second step of adhering the substrate panels to both sides of the
honeycomb core. The adhesion is achieved via the application of
heat (and, also pressure in some cases), which causes the adhesive
resin film to become tacky, and bond the honeycomb core and
substrates together albeit with a primarily chemical bond.
[0009] As with the liquid adhesive, applying a solid adhesive may
not necessarily form a sufficiently strong bond between the
substrates and the honeycomb core for use as a building material.
Also, similar to a liquid adhesive, the strength of solid adhesives
can be dependent upon a uniform bond and a lack of bubbles, voids,
and debris. Furthermore, with a film adhesive that needs heat and
pressure to melt and form the ensuing bond, there is a risk of the
processing temperatures (and pressures in some cases) will melt the
substrates and/or honeycomb core. This risk is enhanced when the
resin adhesive layer, the substrates, and honeycomb core comprise
similar resin materials with similar melting/glass transition
temperatures. Lastly, solid adhesives tend to be expensive and the
additional processing steps associated therewith increase the
chances for reduced product yield due to entrapped contaminants
(dirt, debris, air, etc) to the exposed adhesive portion of the
skin material.
BRIEF SUMMARY OF THE INVENTION
[0010] Implementations of the present invention solve one or more
of the foregoing or other problems in the art with systems,
methods, and apparatus configured to efficiently produce
structured-core laminate panels. Specifically, implementations of
the present invention comprise apparatus and methods for laminating
one or more resin substrate panels to one or more structured cores
using primarily heat and pressure that selectively melts or softens
some components (at least in part) but not others. In at least one
implementation, a manufacturer can create a uniform structured-core
laminate panel with sufficient structural properties for use as a
building material without the use of any adhesives. In particular,
the manufacturer can create a solid structure in which the resin
substrates are melted and bonded to the structured honeycomb
core.
[0011] For example, one implementation of a method of manufacturing
a translucent, structured-core laminate panel in a manner that
substantially resists delamination can involve preparing a laminate
assembly. The laminate assembly can include one or more resin
substrates, which have a first glass transition temperature,
positioned about a structured core having a second melt or glass
transition temperature. The first glass transition temperature of
the resin substrates can be lower than the second melt or glass
transition temperature of the structured honeycomb core.
[0012] The method can also involve heating the laminate assembly to
a processing temperature at least as great as the first glass
transition temperature, but below the second melt or glass
transition temperature; wherein a portion of the one or more resin
substrates flows into the structured core. Additionally, the method
can involve cooling the laminate assembly below the first glass
transition temperature to create a structured-core laminate panel.
The one or more resin substrates can bond to the structured core
without substantial deformation of the structured core, and without
the use of an adhesive film between the one or more resin
substrates and the structured core.
[0013] An implementation of a structured-core laminate panel with
sufficient structural properties for use as a building component
can comprise at least one resin substrate having a first glass
transition temperature. The structured-core laminate panel can also
include at least one structured-core positioned directly against a
first surface of the at least one resin substrate. The at least one
structured core can comprise a plurality of cells, and have a
second melt or glass transition temperature that is substantially
higher than the first glass transition temperature. A portion of
the at least one resin substrate positioned directly against the at
least one structured core is fused to and within the plurality of
cells of the at least one structured core.
[0014] Furthermore, a panel system configured for use as a
partition that provides both light transmission and privacy can
include one or more translucent structured-core laminate panels.
The one or more translucent structured-core laminate panels can
include one or more resin substrates having a first glass
transition temperature. Additionally, the one or more translucent
structured-core laminate panels can include one or more structured
cores including a plurality of cells. The one or more structured
cores can have a second melt or glass transition temperature that
is greater than the first glass transition temperature. Further, a
portion of the one or more resin substrates can extend into and be
fused to the plurality of cells of the one or more structured
cores. The panel system can also include a mounting system that
secures the one or more translucent structured-core laminate panels
to a support structure.
[0015] Additional features and advantages of exemplary
implementations of the invention will be set forth in the
description which follows, and in part will be obvious from the
description, or may be learned by the practice of such exemplary
implementations. The features and advantages of such
implementations may be realized and obtained by means of the
instruments and combinations particularly pointed out in the
appended claims. These and other features will become more fully
apparent from the following description and appended claims, or may
be learned by the practice of such exemplary implementations as set
forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] In order to describe the manner in which the above-recited
and other advantages and features of the invention can be obtained,
a more particular description of the invention briefly described
above will be rendered by reference to specific embodiments thereof
which are illustrated in the appended drawings. It should be noted
that the figures are not drawn to scale, and that elements of
similar structure or function are generally represented by like
reference numerals for illustrative purposes throughout the
figures. Understanding that these drawings depict only typical
embodiments of the invention and are not therefore to be considered
to be limiting of its scope, the invention will be described and
explained with additional specificity and detail through the use of
the accompanying drawings in which:
[0017] FIG. 1 illustrates a facing view of a structured-core
laminate panel surface in accordance with an implementation of the
present invention;
[0018] FIG. 2 illustrates a cross-sectional view of the
structured-core laminate panel of FIG. 1 taken along the line 2-2
of FIG. 1;
[0019] FIG. 3A illustrates a side, cross-sectional view of a
laminate assembly in accordance with an implementation of the
present invention that a manufacturer may use in forming a
structured-core laminate panel, such as shown in FIGS. 1-2;
[0020] FIG. 3B illustrates an exploded perspective-view of the
laminate assembly of FIG. 3A;
[0021] FIG. 4A illustrates a side, cross-sectional view of another
laminate assembly that a manufacturer may use in forming a
structured-core laminate panel in accordance with an implementation
of the present invention;
[0022] FIG. 4B illustrates an exploded perspective-view of the
laminate assembly of FIG. 4A;
[0023] FIGS. 5A-5C illustrate a sequence of side, cross-sectional
views of the laminate assembly of FIG. 3A when subjected to
temperatures and pressures in accordance with an implementation of
the present invention;
[0024] FIG. 6 illustrates a facing view of another structured core
laminate panel in accordance with an implementation of the present
invention;
[0025] FIG. 7 illustrates a cross-sectional view of the
structured-core laminate panel of FIG. 6 taken along the line 7-7
of FIG. 6;
[0026] FIG. 8 is schematic view of panel system including a
structured-core laminate panel secured to a support structure as a
sliding door; and
[0027] FIG. 9 illustrates a chart of acts and steps in a method of
forming a structured core laminate panel in accordance with an
implementation of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] The present invention extends to systems, methods, and
apparatus configured to efficiently produce structured-core
laminate panels. Specifically, implementations of the present
invention comprise apparatus and methods for laminating one or more
resin substrate panels to one or more structured cores using
primarily heat and pressure that selectively melts or softens some
components (at least in part) but not others. In at least one
implementation, a manufacturer can create a uniform structured-core
laminate panel with sufficient structural properties for use as a
building material without the use of any adhesives. In particular,
the manufacturer can create a solid structure in which the resin
substrates are melted and bonded to the structured honeycomb
core.
[0029] In general, and as understood more fully herein, a
manufacturer can use resin materials that have different glass
transition temperatures to melt the interface layers of the resin
substrate(s) adjacent a polymer-based structured core (e.g.,
honeycomb cellular structure). Specifically, the manufacturer uses
a structured core (having cells with any number of different sizes
and formations/alignments) prepared from a polymer-based material
having relatively high glass transition temperature, and one or
more resin sheets having a relatively low glass transition
temperature. In at least one implementation, the relatively high
glass transition temperature material comprises polycarbonate,
and/or composites or mixtures thereof. By contrast, in at least one
implementation, the relatively low glass transition temperature
material of the resin substrate(s) used in lamination comprises a
copolyester material, acrylic material, and/or composites or
mixtures thereof.
[0030] The difference in melt or glass transition temperatures
between the resin substrates and the structured core can allow a
manufacturer to heat and press a portion of the resin substrates
into the cells of the structured core without melting or otherwise
compromising the structure or strength of the structured core. Upon
cooling, portions of the resin substrates within the structured
core can form a mechanical bond unifying the resin substrates and
the structured core. In some implementations, in addition to the
mechanical bond, a chemical bond can form between the resin
substrates and the structured core.
[0031] In any event, the bond between the resin substrates and the
structured core can be stronger than chemical bonds formed by
adhesives. Furthermore, in some implementations, the strength of
the bond is independent of uniformity or a lack of bubbles, voids,
and debris. Thus, implementations of the present invention can
allow for repeated formation of structurally sound panels without
the risk of panels with a defective bond.
[0032] Implementations of the present invention can thus produce
strong and aesthetically pleasing structured-core laminate panels.
In particular, structured-core laminate panels of the present
invention can be lightweight due to the cellular structured-core,
yet durable and strong. In particular, structured-core laminate
panels of the present invention can have load-bearing
characteristics and properties sufficient to allow manufacturers to
use the panels as building materials. In particular,
structured-core laminate panels of the present invention can be
sufficiently strong to avoid delamination even under extreme
conditions, such as dynamic and static loads, wide fluctuations in
temperature, peeling forces or forceful impacts.
[0033] Additionally, as mentioned previously, in addition to
excellent structural properties, structured-core laminate panels of
the present invention can also provide unique and desirable
aesthetics. For example, implementations of structured-core
laminate panels can be translucent and allow light transmission
there through. Designers can use such translucent structured-core
laminate panels in lighting applications, such as light boxes, or
as window coverings. Furthermore, the structured core and/or colors
of the panels can provide varying degrees
transparency/translucency, and thus, varying degrees of privacy.
Thus, designers can use structured-core laminate panels of the
present invention as partitions, doors, or dividers where varying
degrees of privacy are desired.
[0034] Accordingly, and as will be appreciated more fully from the
following specification and claims, a structured-core laminate
panel in accordance with an implementation of the present invention
can have aesthetic and functional versatility, and function in a
wide variety of installations. In particular, designers can use the
structured-core laminate panels described herein in any number of
ceiling, floor, or wall applications, whether in indoor or outdoor
environments, including any residential, commercial, or industrial
environments. For example, structured-core laminate panels
described herein can serve a primarily functional or structural use
as a building component. In addition, the structured-core laminate
panels described herein can function primarily for
aesthetic/decorative use, such as to apply a particular look,
and/or texture to a wall, column, or lighting element/arrangement
in an interior or exterior space.
[0035] Referring now to the Figures, FIGS. 1 and 2 illustrate a top
view and side view, respectively, of a structured-core laminate
panel 100. The structured-core laminate panel 100 comprises a
structured-core 102 laminated to one or more resin substrates
104(a, b). As shown by FIG. 2, in some implementations of the
present invention the structured-core laminate panel 100 includes a
structured core 102 laminated between opposing upper 104a and lower
104b resin substrates. In alternative implementations, however, the
structured-core laminate panel 100 can comprise a structured core
102 laminated to a single resin substrate 104.
[0036] As used herein, the terms "resin-based substrate," "resin
substrate," "polymer-based substrate," "polymer substrate,"
"resin-based sheet" or "resin sheet" means a substrate comprising
materials of one or more layers or sheets formed from any one of
the following thermoplastic polymers (or alloys thereof).
Specifically, such materials include but are not limited to,
polyethylene terephthalate (PET), polyethylene terephthalate with
glycol-modification (PETG), acrylonitrile butadiene-styrene (ABS),
polyvinyl chloride (PVC), polyvinyl butyral (PVB), ethylene vinyl
acetate (EVA), polycarbonate (PC), styrene, polymethyl methacrylate
(PMMA), polyolefins (low and high density polyethylene,
polypropylene), thermoplastic polyurethane (TPU), cellulose-based
polymers (cellulose acetate, cellulose butyrate or cellulose
propionate), or the like. Furthermore, the resin substrates can
include other thermoplastic polymers or thermoplastic polymer
blends, or combinations and mixtures thereof. In addition, any
given resin substrate or sheet can include one or more resin-based
substrates and any number other layers or coatings.
[0037] For example, the structured-core laminate panel 100 shown in
FIGS. 1 and 2 includes single-layered resin substrates 104a, 104b.
One will appreciate, however, that the structured-core laminate
panel 100 can alternatively comprise a laminate of multiple
resin-based substrates 104 of the same or different materials as
those described above. The resin substrates 104 can vary in
thickness to include a range from relatively thin gauge films to
thicker gauge sheets (e.g., greater than about one-sixteenth inch (
1/16'') to about 5 inches (5'')).
[0038] For example, in some implementations, the gauge of the
structured-core laminate panel 100 in at least one implementation
can be anywhere from about one-sixteenth inch ( 1/16'') to about
two inches (2'') inches. The thickness of the structured-core
laminate panel 100 can be based at least partially on the number of
resin-based substrates it comprises, as well as the desired
end-use. Furthermore, when upper 104a and lower 104b resin
substrates are used, as in the structured-core laminate panel 100
of FIGS. 1 and 2, the upper resin substrate 104a can comprise the
same thermoplastic materials as the lower resin substrate 104b.
Alternatively, the upper 104a and lower 104b resin substrates can
comprise differing thermoplastic materials.
[0039] In any event, the resin substrates 104 can include
thermoplastic materials that a manufacturer can heat sufficiently
above their glass transition temperature to soften, and then
subsequently cool to solid form. More specifically, the resin
substrates 104 can have a glass transition temperature lower than
the melt or glass transition temperature of the structured core
102. Thus, one will appreciate that a manufacturer can select the
thermoplastic materials of the resin substrates 104 based upon the
materials of the structured core 102, or vice versa. As explained
in greater detail below, the differences in melt or glass
transition temperatures between the resin substrates 104 and the
structured core 102 can allow a manufacturer to soften and press a
portion of the resin substrates 104 into the cells 108 of the
structured core 102 without melting or otherwise compromising the
structure or strength of the structured core 102.
[0040] As used herein, the term "structured-core" means a structure
including a plurality of cells or hollow chambers. For example, the
structured-core 102 of FIGS. 1 and 2 includes a plurality of
cylindrically-shaped cells 108. In alternative implementations, the
structured core 102 can comprise honeycomb cells or cells of
virtually any other shape or size. For instance, the
structured-core can include cells having a tubular, diamond,
square, circular, or virtually any other shape. No matter the
configuration, the structured-cores of the present invention can
include cells or hollow chambers within which softened or melted
resin of the resin substrates 104 can flow into create a mechanical
bond as explained in greater detail below. For example, as shown by
FIGS. 1 and 2, the structured core 102 can include
cylindrically-shaped cells 108 that are oriented perpendicularly to
the abutting surfaces of the resin substrates 104a, 104b.
[0041] The structured core 102 can comprise thermoplastic
materials, such as those previously mentioned in relation to the
resin substrates 104. In alternative implementations, the
structured core 102 can comprise glass, metal or other materials.
Thus, the structured core 102 can comprise a wide variety of
materials so long as the structured core has a higher melt or glass
transition or melting temperature than that of the outer, adjacent
resin substrate(s) 104. As mentioned previously, the higher melt or
glass transition or melting temperature of the structured core 102
can ensure that a manufacturer can soften or melt the resin
substrates 104 sufficiently to press a portion of the resin
substrates into the structured core 102, without softening (at
least not in a damaging way) the structured core 102.
[0042] In any case, in at least one implementation, the resin
substrates 104a, 104b and/or the structured core 102 (or both) can
be substantially translucent or transparent. Indeed in some
implementations, at least the structured core 102 is substantially
translucent, such that a significant amount of light can pass
through the structured-core laminate panel 100. As previously
mentioned, a manufacturer can use such translucent structured-core
laminate panels 100 in lighting applications or as a semi-private
divider. In alternative implementations, the resin substrates 104a,
104b and/or the structured core 102 (or both) can be opaque.
[0043] FIG. 3A illustrates an overview of a laminate assembly 120
for use as a precursor in creating a structured-core laminate panel
100. Similarly, FIG. 3B illustrates an exploded view of the
components of the laminate assembly 120 of FIG. 3A, albeit rotated
into a 3D view. In particular, FIGS. 3A-3B illustrate a sequential
overview in accordance with an implementation of the present
invention for positioning components of the laminate assembly 120
prior to subjecting the components to a lamination process.
[0044] For example, FIGS. 3A-3B illustrate that a laminate assembly
120 in accordance with an implementation of the present invention
can include opposing resin-based substrates or sheets 104a, 104b.
Each resin substrate 104a, 104b can include an outer surface 110,
and an opposing inner surface 106. The resin-based substrates 104a,
104b can be formed from any of the materials described herein above
in defining "resin-based," and can be translucent or transparent.
Additionally, the resin-based substrates 104a, 104b can comprise a
laminate of multiple layers of the same or different compatible
materials.
[0045] Furthermore, the resin-based substrates 104a, 104b can be
any appropriate thickness for the resulting thickness of a final
structured-core laminate panel 100, such as about two inches (2''),
about one inch (1''), about one-half inch (1/2''), about one-fourth
inch (1/4''), about one-eighth inch (1/8''), about one-sixteenth
inch ( 1/16''), or about one-thirty-second inch ( 1/32'') in
thickness or gauge as desired. In some implementations of the
present invention, the opposing resin substrates 104a, 104b can
have similar thicknesses as shown in FIGS. 3A and 3B. In
alternative implementations, the thicknesses of the resin
substrates 104a, 104b may differ. For example, a manufacturer may
intend to use the resulting structured-core laminate panel 100 as a
floor structure, and therefore, increase the thickness of one of
the resin substrates 104a, 104b upon which people will walk.
[0046] Additionally, the size (i.e., surface area of sides 106 or
110) of the resin-based substrates 104a, 104b can also be any
appropriate size for the desired size of resulting structured-core
laminate panel 100. In at least one implementation, for example,
the resin-based substrate 104a, 104b can be about four feet by
about eight feet (4'.times.8'), about four feet by about ten feet
(4'.times.10'), about six feet by about fifteen feet
(6'.times.15'), or taller/wider. Or alternatively, the resin-based
substrate 104a, 104b can be about six inches by about six inches
(6''.times.6'') or shorter/skinnier. Thus, a manufacturer can
tailor both the gauge and size of the resin-based substrate 104a,
104b depending upon the desired dimensions of a resulting
structured-core laminate panel 100.
[0047] The structured core 102 can have any size relative to the
size (i.e., surface area) as the surfaces 106 of the resin-based
substrates 104a, 104b. For example, FIGS. 3A and 3B illustrate that
the structured core 102 can have approximately the same size (i.e.,
surface area) as the surfaces 106 of the resin-based substrates
104a, 104b against which the structured core 102 is abutted.
Alternatively, the resin substrates 104a, 104b can extend beyond
the edges of the structured core or vice versa.
[0048] FIGS. 3A-3B also depict that the laminate assembly 120 can
include one or more structured cores 102 placed next to, or
against, one or more surfaces 106 of the resin-based substrates
104a, 104b. As shown in FIGS. 3A-3B, a manufacturer can abut the
structured core 102 directly against the adjacent surfaces 106 of
the resin substrates 104a, 104b without out any intervening
adhesive liquids, films or other layers. This can ensure that resin
of the resin substrates 104a, 104b are mechanically and/or
chemically bonded directly to the structured core 102 during the
lamination process.
[0049] In some cases, the manufacturer may also include other
decorative items between or on the outer surfaces 110 of the resin
substrate(s) 104a, 104b in order to add any number of decorative
effects. For example, FIGS. 4A-4B illustrate another implementation
of a laminate assembly 120a that includes a decorative image layer
122. In particular, FIG. 4A illustrates a cross-sectional view of a
laminate assembly 120a for use as a precursor in creating
structured-core laminate panel. Similarly, FIG. 4B illustrates an
exploded view of the components of the sublimation laminate
assembly 120a in FIG. 4A, albeit rotated to show as a 3D view.
[0050] One will appreciate that there are a wide variety of
decorative image layers that a manufacturer can add to the laminate
assembly 120a to create a wide variety of effects. For example, the
decorative image layer can comprise fabric, metallic wire, rod
and/or bar, papers or printed or photographic images, crushed
glass, and vegetation, such as wood chips, grasses, flowers, wheat,
and thatch. The decorative image layer may display images or
decorative designs or may be of a solid color. The melting point of
the decorative image layer should be sufficiently high to avoid any
degradation or distortion of the decorative image layer during the
manufacture or processing of the laminate assembly. In some
implementations, the decorative image layer(s) 122 is substantially
continuous, and constitutes a distinct image layer or laminate,
such as the decorative image layer 122 in FIGS. 4A and 4B.
Alternatively, the decorative image layer(s) 122 can be made of
discontinuous segments, particularly when the decorative image
layer comprises wire or vegetation.
[0051] As shown in FIGS. 4A and 4B, in some implementations the
decorative images layer 122 can comprise one or more color or
performance film layers (such as a light diffusion layer or graphic
film). With particular regard to a colored film layer, the
decorative image layer 122 can impart a color to the
structured-core laminate panel 100 during the lamination process
(e.g., as opposed to having already provided color during
extrusion). The decorative image layer 122, when a color film,
preferably ranges from about 0.0254 mm (0.001 inch) to about 1.524
mm (0.06 inch) in thickness, and more preferably 0.0254 mm (0.001
inch) to 0.05 mm (0.002 inch), and most preferably about 0.04 mm
(0.0015 inch) in thickness. Polymeric films thinner or thicker may
be used in the decorative image layer 122, depending on the
equipment available, and under such conditions the thickness is
limited only by functionality. Furthermore, a manufacturer can
combine different colored films in the decorative image layer 122
to make a single, uniformly colored structured-core laminate panel
100.
[0052] Combination through lamination or adhesion of such film
layers of differing colors creates a uniform colored panel that is
a composite color of the individual film colors used to construct
the laminate assembly 120a. Furthermore, so long as the colors
selected are effectively transparent, the color ordering of colored
films is not important as the color and hue of the panel remains
the same throughout the finished panel regardless of viewing
direction and ordering of the films on or within the resin
substrates 104. In addition to varying the color of a resulting
structured-core laminate panels 100, a manufacturer can use the
decorative image layer 122 (and any films making up the decorative
image layer 122) to vary the hue and/or translucency of a resulting
structured-core laminate panel 100.
[0053] FIGS. 4A and 4B illustrate that a manufacturer can place the
decorative image layer 122 against one or more of the outer
surfaces 110 of the resin substrates 104a, 104b. For example, FIGS.
4A and 4B illustrate a decorative image layer 122 against the outer
surface 110 of the upper resin substrate 104a. In addition to the
decorative image layer 122, FIGS. 4A and 4B illustrate that the
manufacturer can add yet another outer resin substrate 104c to the
laminate assembly 120a. One will appreciate that, in some cases,
the manufacturer could omit resin substrate 104b on one side and
keep substrates 104a and 104c on the other side of the structured
core 102.
[0054] Additionally, the decorative image layer 122 need not
necessarily be between two outer resin substrates 104b and 104c.
For example, in at least one implementation, a manufacturer can
position the decorative image layer 122 between the substrate 104b
and/or 104a so that the decorative image layer 122 interfaces
between the structured core 102 and the resin substrate(s) 104a,
104b. In further implementations, the manufacturer can apply the
decorative image layer 122 directly to the outside surface 110 of
substrate 104a (and/or 104b), as shown, but omit the third resin
substrate 104c (or any other possible additional substrates
104--not shown). In either case, the manufacturer can achieve
essentially the same color result in the resulting structured-core
laminate panel 100.
[0055] Still further, one will appreciate that the manufacturer can
construct the laminate assembly 120, 120a with a wide range of
thermoplastic materials, which provide suitable properties in
accordance with implementations described herein. In one
implementation, for example, the manufacturer can use a structured
core 102 comprised of polycarbonate materials, but use resin
substrates 104 comprising glass transition temperatures that are
lower than that for polycarbonate. Such lower glass transition
temperature materials used in resin substrates 104 can comprise of
any number of thermoplastic sheet materials including copolyesters,
acrylic materials, and/or mixtures thereof.
[0056] In one implementation, in particular, the manufacturer
prepares a laminate assembly 120, 120a with a polycarbonate
structured core 102, and further with acrylic materials as the next
adjacent resin substrate(s) 104a or 104b. The manufacturer can
further use a colored film layer as a decorative layer 122 adjacent
the acrylic layer 104a or 104b, whereby the thin colored film
decorative layer 122 comprises colorant loaded acrylic films
(although other colored thin films such as EVA or TPU may be
utilized). In this implementation, the manufacturer can also
optionally use another outer layer 104c, though this is not
required for all implementations. In such a case, the other outer
layer 104c adjacent the colored film decorative layer 122 can
comprise a thermoplastic sheet such as acrylic or copolyester
(e.g., PETG), or mixtures thereof.
[0057] In another implementation, the manufacturer prepares a
laminate assembly 120, 120a with a polycarbonate structured core
102, and further uses acrylic or copolyester uniformly for all of
the resin substrate layers 104a, 104b, and/or 104c, and the colored
film decorative layer 122. In still further implementations, the
manufacturer prepares a laminate assembly 120a using all three (or
more) illustrated substrates 104a, 104b, and 104c (or more than
those illustrated), and further applies a colored film decorative
layer 122 to the outside thereof (e.g., on the outer surface 110 of
substrate 104c).
[0058] In addition to the foregoing, the manufacturer may apply
other components to the laminate assembly as may be required for
applying temperature and pressure. In one implementation using
conventional heat presses (thereby utilizing mechanical pressure
and conductive heating and cooling), for example, the manufacturer
can surround the sheet laminate assembly with one or more pressure
pads, one or more metal plates, and/or one or more texture papers
(to impart still further aesthetic effects). The pressure pads
and/or metal plates can equalize pressure and temperature across
the entire surface of the laminate assembly 120, 120a. By contrast,
the texture papers can impart any number of different textures or
glosses on the resin substrates 104 during lamination.
[0059] Upon preparing the laminate assembly 120, 120a, the
manufacturer then applies appropriate heat and pressure to form a
structured-core laminate panel 100. In at least one implementation,
the manufacturer applies enough heat and pressure to cause the one
or more resin substrates 104a, 104b to melt at the interface with
the structured core 102, without causing the structured core 102 to
melt or deform. Furthermore, the temperature and pressure can be
sufficient to avoid causing any deformation in the outer surfaces
110 of the resin substrates 104a, 104b, 104c, such as any dimpling
due to collapse on an opposing side of the resin substrate 104 into
any particular cell/chamber 108.
[0060] In particular, the manufacturer can heat the sheet assembly
120, 120a to a processing temperature sufficient to soften or at
least partially melt the resin substrates 104, but not high enough
to soften or melt the structured core 102. Thus, the manufacturer
can heat the sheet assembly to a processing temperature at least as
great as the glass transition temperature of the resin substrate(s)
104, but below the melt or glass transition temperature of the
structured core 102. Along related lines, the manufacturer can
apply a processing pressure to the laminate assembly 120, 120a
sufficient to cause softened or melted resin of the resin
substrates 104a, 104b to flow into the cells 108 of the structured
core 102, but not so great as to damage the structured core
102.
[0061] In at least one implementation, the processing temperature
is between about 180.degree. F. and about 295.degree. F. One will
appreciate that varying resins can have a wide range of glass
transition temperatures, and thus, the processing temperature can
vary depending on which resins are used. For example, in an
implementation using a polycarbonate structured core 102 and
copolyester (e.g., PETG, PET, and PCTG) resin substrates 104, the
appropriate processing temperature may be between about 180.degree.
F. to about 275.degree. F. Alternatively, when using a
polycarbonate structured core 102 and acrylic (e.g., PMMA) resin
substrates 104, the appropriate processing temperature may be
between about 190.degree. F. to about 295.degree. F., depending
largely on the applied pressure.
[0062] For example, in at least one implementation, the
manufacturer can implement a processing pressure that is between
approximately 5 pounds per square inch (psi) and approximately 250
psi, and preferably between about 5 psi and about 50 psi for each
such material. In an implementation in which the structured core
102 comprises polycarbonate and the opposing resin substrate(s) 104
comprise a copolyester material, the appropriate pressure can be
about 40 psi.
[0063] As discussed herein, the structured core 102 in
implementations of the present invention does not deform in any
appreciable way since the above-mentioned temperatures do not
elevate the materials of the structured core 102 to its melt or
glass transition temperature (i.e., polycarbonate has a glass
transition temperature that is usually achieved at temperatures
higher than 300.degree. F.). Similarly, the noted temperatures and
pressures of the present invention do not elevate the materials of
the structured core 102 to heat distortion temperatures. At a
pressure of about 66 psi, the heat distortion temperature for a
polycarbonate structure would be about 280.degree. F. Of course,
however measured, the primary point in at least one implementation
is that the polycarbonate structured core 102 will not be at its
glass transition temperature or heat distortion parameter(s), even
if the adjacent resin substrate(s) 104 is at such parameters.
[0064] One will appreciate that a manufacturer can apply the
processing temperature(s) and pressure(s) to the laminate assembly
120, 120a to form a structured-core laminate panel 100 in any
number of different apparatus. For example, in some implementations
the manufacturer can place the laminate assembly 120, 120a within a
thermosetting press. In general, the thermosetting press can
include upper and lower platens configured to provide direct heat
and pressure to both opposing sides of the given laminate assembly
120, 120a.
[0065] In addition to the foregoing, implementations of the present
invention further include using an autoclave to apply the
processing temperatures and pressures. For example, the
manufacturer can place the laminate assembly 120, 120a into a
vacuum bag. The manufacturer can then seal the edges of the vacuum
bag, and remove air from the vacuum bag. The manufacturer can then
place the vacuum bag within the autoclave, which applies equal heat
and pressure in all directions on the laminate assembly 120, 120a.
In general, an autoclave can heat the laminate assembly 120, 120a
(e.g., via a convection process, rather than via conduction as with
a mechanical press) with a controlled temperature profile.
[0066] One will appreciate that the autoclaving process can provide
a number of additional benefits for creating an appropriate,
aesthetically pleasing, structured-core laminate panel 100. For
example, autoclaving is typically not constrained to one
size/format (i.e., an autoclave can process a 2'.times.4' piece at
the same time as an 8'.times.10' piece). In addition, in the
autoclaving process, pressure can be continuous throughout heating
and cooling cycles. This continuous pressure can keep the laminate
assembly 120, 120a flat throughout the heating and cooling cycles,
which can eliminate bowing. Further along these lines, autoclaving
is a convective heating process that allows for more controlled
heating and cooling at each direction about the sublimation
assembly, and thus allows for equal temperatures at the same depth
throughout each corresponding substrate's thickness. Again, since
the temperature, and pressure, is uniformly distributed throughout
each substrate, the autoclave can process multiple different
sublimation assemblies without any warping/bowing, etc.
[0067] In addition to an autoclave process, yet another
implementation for heating and pressurizing a laminate assembly
120, 120a can include use of a vacuum press. In particular, and as
previously mentioned with respect to the autoclave process, a
manufacturer can prepare a vacuum bag with a laminate assembly 120,
120a therein. The manufacturer can then position the vacuum bag
into a vacuum press, and apply the appropriate processing
temperatures and pressures. In another implementation, a
manufacturer can place a laminate assembly 120, 120a (without a
vacuum bag) in a vacuum press chamber, where air is evacuated prior
to application of mechanical pressure.
[0068] FIGS. 5A-5C illustrate a sequence of physical changes in an
exemplary laminate assembly 120 being subjected to the appropriate
processing temperature T and processing pressure P. For example,
FIG. 5A illustrates a cross-sectional view of a laminate assembly
120. As shown in FIG. 5A, a manufacturer can apply processing
temperature T and processing pressure P to the laminate assembly
120 using a thermosetting press, autoclave, vacuum press, or other
thermosetting apparatus.
[0069] FIG. 5B illustrates the changes that the resin substrates
104a and 104b can undergo as the temperature of the resin
substrates 230 reaches the processing temperature T (i.e., a
temperature at or above the glass transition temperature of the
resin substrates 104a, 104b). In particular, FIG. 5B illustrates
that as the laminate assembly 120 reaches the processing
temperature T, the resin substrates 104a, 104b begin to soften. In
at least one implementation, the manufacturer applies the above
processing pressure and temperature for about 11 minutes, of which
about 6 minutes is raising the temperature in this range, while the
remaining 5 minutes comprises holding materials at about
225.degree. F. In alternative implementations the manufacturer can
apply the above processing pressure and temperature for time
intervals of greater than 11 minutes, or even less than 11
minutes.
[0070] In any event, during this time interval, the resin
substrates 104a, 104b begin to flow, particularly at the inner
surfaces 106 abutting the structured core 102. As discussed, this
generally occurs since the temperatures and pressures are
sufficient to cause the resin substrate materials to meet or exceed
their respective glass transition temperatures. As shown in FIG.
5B, for example, this causes the resin substrates 104a, 104b to
deform at the respective inner surfaces 106.
[0071] FIG. 5C illustrates that once the resin materials of the
resin substrates 104a, 104b have begun to melt, the pressure P
causes resin to at least partially flow around, in, and/or through
the chambers/cells 108 of the structured core 102. Nevertheless,
the resin substrates melt in or around the cells 108 without
causing significant melting or deformation of the structured core
102, or deforming the outer surfaces 110 of the resin substrates
104a, 104b. In particular, as the inner surfaces 106 of the resin
substrates 104a, 104b become tacky, the resin materials at least
partly mechanically attach to the structured core 102.
Additionally, in some cases the resin materials also fuse to the
structured core 102 and corresponding cells/chambers 108. As a
result, one will appreciate that the bond between structured core
102 and resin substrates 104a, 104b is much stronger than
conventional laminations.
[0072] FIG. 5C further illustrates that the final result of the
lamination process (i.e., after resin substrates 104a, 104b have
cooled below their respective glass transition temperatures)
includes one or more resin substrates 104a, 104b seamlessly bonded
to a structured core 102. In particular, FIG. 5C illustrates that
resin portions 124 of the resin substrates 104a, 104b extend into
the cells/chambers 108 of the structured core 102. One will
appreciate that by extending into the cells/chambers 108 of the
structured core 102 the surface area of the bond between the resin
substrates 104a, 104b is increased, thereby increasing the strength
of the bond.
[0073] In addition, in implementations including a decorative image
layer 122, such as a color film layer, and additional outer resin
substrate(s) 104c, the processing temperatures and pressures will
cause the outer surface 110 of the resin substrate 104c and the
inner surface 106 of the resin substrate 104a to soften, become
tacky and bond to the decorative image layer 122, and/or each
other. In at least one implementation, such as where the resin
substrate layers 104a and/or 104b, and 104c are translucent, the
resin substrate layers 104 will substantially exhibit the color of
the color film, often without any clear visual evidence of the
presence of the color film in the final structured-core laminate
panel 100.
[0074] As previously mentioned, manufacturers can modify
implementations of the present invention in any number of ways to
achieve a wide range of functional and/or aesthetic effects. In at
least one implementation of the present invention, for example, the
structured-core laminate panel 100 comprises one or more at least
partly translucent resin substrates. The resin substrates can
further comprise coloration in one form or another, such as by
further including any dyes during the resin extrusion process, or
by laminating still further colored films directly to the
substrates (before, during, or after lamination with the structured
core). In addition, one will appreciate that the structured cores
themselves can be varied for a wide range of functional and/or
aesthetic effects. For example, the structured cores can be varied
in terms of size, pattern, cell geometry, spacing, depth,
thickness, color, material, and translucence.
[0075] For example, FIGS. 6 and 7 illustrates views of another
structured-core laminate panel 100a in accordance with the present
invention. Specifically, FIG. 6 illustrates a top view of the
structured-core laminate panel 100a, while FIG. 7 illustrates a
cross-sectional view of the structured-core laminate panel 100a
taken along the line 7-7 of FIG. 6. As shown by FIGS. 6 and 7, the
structured-core laminate panel 100a can include a structured core
102a laminated to opposing resin substrates 104a, 104b. More
particularly, the structured core 102a can comprise a honeycomb
structure with honeycomb cells 108a.
[0076] As shown by FIG. 6, the resin substrate 104a can be
translucent, and can allow a user to view the honeycomb cells 108a
therethrough. As previously mentioned, the cells of the structured
core can include any number of geometries depending upon a desired
aesthetic. For example, FIG. 6 illustrates that of the cells 108a
of the structured core 102a can have the shape of a Reuleaux
triangle. One will appreciate that the Reuleaux triangle shape of
the cells 108a can provide a unique and desirable aesthetic.
[0077] Furthermore, FIG. 7 illustrates that resin portions 124 of
the resin substrates 104a, 104b can harden into a mushroom shaped
plug, which can result in a mechanical interlock with the cells
108a. Thus, the lamination process of the present invention can
form a bond between the resin sheets 104a, 104b and the structured
core 102a that is sufficiently strong to avoid delamination even
under extreme conditions. Such extreme conditions may include
dynamic and static loads, wide fluctuations in temperature, peeling
forces or forceful impacts. In view of such properties, one will
appreciate that the structured-core laminate panels 100, 100a made
in accordance with the present invention can function in a wide
range of applications, including as building components.
[0078] For example, FIG. 8 illustrates a panel system 100 including
a structured-core laminate panel 100b. More particularly, FIG. 8
illustrates a mounting system 132 (i.e., sliding door suspension
tracks) securing a structured-core laminate panel 100b to a support
structure 134 as a sliding door. One will appreciate that the
structured-core laminate panel 100b may be particularly suited for
use as a partition, such as a sliding door, because of its
lightweight yet strong configuration.
[0079] Furthermore, one will appreciate that the cells of the
structured-core laminate panel 100c can provide a unique aesthetic.
As mentioned previously, the cells of the structured core can have
a wide variety of shapes and configurations. Additionally, the
cells 108 of a particular structured-core laminate panel need not
be uniform. For example, FIG. 8 illustrates a structured core
including cells 108 with various different sizes (i.e., large sized
cells 108b, medium sized cells 108c, and small sized cells
108d).
[0080] One will appreciate that a manufacturer can design or
configure the structured core to provide varying degrees of
privacy. Thus, the structured-core laminate panel 100b can function
as a partition that provides both light transmission and privacy.
Indeed, a manufacturer can modify the color and
opacity/translucence of the structured-core laminate panel 100b in
any number of ways to adjust the opacity/transparency of the
structured-core laminate panel 100b for desired aesthetic effect.
For instance, in at least one implementation, a manufacturer can
modify the hue, color intensity, and light transmission of the
structured core and/or the decorative image layer 122 to vary the
resultant aesthetic properties of the structured-core laminate
panel 100b. Accordingly, one will appreciate that implementations
of the present invention provide a manufacturer with a number of
ways to prepare a structurally useful, aesthetically desirable
panel. These panels can have a wide range of shapes, sizes,
thicknesses, properties or colors, and can be used in a wide range
of environments and applications.
[0081] Accordingly, FIGS. 1-8, the corresponding text, provide a
number of different components and mechanisms for creating
structured-core laminate panels 100 in an efficient, aesthetically
pleasing way. In addition to the foregoing, implementations of the
present invention can also be described in terms of flowcharts
comprising acts and steps in a method for accomplishing a
particular result. For example, FIG. 9 illustrates a flowchart of
one exemplary method for producing a structured-core laminate panel
100, 100a, 100b using principles of the present invention. The acts
of FIG. 9 are described below with reference to the components and
diagrams of FIGS. 1 through 8.
[0082] For example, FIG. 9 shows that a method of creating a
structured-core laminate panel 100c comprises an act 200 of
preparing a laminate assembly 120, 120a. Act 200 includes
positioning one or more resin substrates about a structured core.
More specifically, act 200 includes positioning one or more resin
substrates having a first glass transition temperature about a
structured core having a second melt or glass transition
temperature greater than the first glass transition temperature.
For instance, a manufacturer can position resin substrates 104a,
104b, 104c formed from a copolyester or acrylic material about a
structured core 102, 102a formed from a polycarbonate material. The
manufacturer can then place the opposing resin substrates 104a,
104b directly against a structured core 102, 102a without any
adhesive films or other layers between the resin substrates 104a,
104b and the structured core 102, 102a.
[0083] In addition, FIG. 9 shows that the method can comprise an
act 210 of heating the laminate assembly 120, 120a. Act 210
includes heating the laminate assembly to a processing temperature
at least as great as the glass transition temperature of the outer
substrates 104a, 104b but below the melt or glass transition
temperature of the structured core 102, 102a. In connection with
act 210, a portion of the one or more resin substrates flows into
the structured core. For example, a manufacturer can heat the
laminate assembly 120, 120a to a temperature of between about
180.degree. F. and about 275.degree. F., such as to a temperature
of about 225.degree. F. The manufacturer can heat the laminate
assembly in a lamination press, autoclave, vacuum bag, or other
thermosetting environment. In an autoclave, a manufacturer may
further perform the lamination by inserting the materials of the
above-described laminate assembly into a vacuum bag.
[0084] FIG. 9 also shows that the method comprises act 220 of
cooling the laminate assembly. Act 220 can include cooling the
laminate assembly below the first glass transition temperature to
create a unitary structured-core laminate panel. For example, a
manufacturer can place the laminate assembly 120, 120a into a cold
press or simply position can position the laminate assembly 120,
120a so that ambient air can cool the laminate assembly 120, 120a.
Upon cooling, portions 124 of the resin substrates 104a, 104b
within the structured core 102, 102a can harden and form a
mechanical bond unifying the resin substrates 104a, 104b and the
structured core 102, 102a. In some implementations, in addition to
the mechanical bond, a chemical bond can form between the resin
substrates 104a, 104b and the structured core 102, 102a.
[0085] Accordingly, the schematics and methods described herein
provide a number of unique products, as well as ways for creating
aesthetically pleasing, decorative, architecturally-suitable panels
with structured cores. As discussed herein, these panels can be
substantially translucent or transparent in order to provide a
desired aesthetic. Furthermore, the implementations of the present
invention provide methods of bonding a structured core to one or
more resin substrates without damaging or degrading the structured
core during processing. Accordingly, implementations of the present
invention can create not only a structured-core laminate panel with
pleasing aesthetics, but also a panel that is sufficiently strong
to avoid delamination even under extreme conditions.
[0086] The present invention may be embodied in other specific
forms without departing from its spirit or essential
characteristics. The described embodiments are to be considered in
all respects only as illustrative and not restrictive. The scope of
the invention is, therefore, indicated by the appended claims
rather than by the foregoing description. All changes that come
within the meaning and range of equivalency of the claims are to be
embraced within their scope.
* * * * *