Panel structure

• US 10,647,083 B2
• Filed: 06/20/2017
• Issued: 05/12/2020
• Est. Priority Date: 06/18/2004
• Status: Active Grant

• Current Assignee: Zephyros, Inc.
• Original Assignee: Zephyros, Inc.
• Inventors: Carlson, David, Madaus, Brandon, Harthcock, Matthew, Barton, Kearney, Taylor, Charles L., Walker, Jason
• Primary Examiner(s): Grun, Robert J
• Application Number:
  US15/628,055
• Publication Number:
  US 20170282486A1
• Time in Patent Office: 1,057 Days
• Field of Search: None
• CPC Class Codes: B29C 44/1228 Joining preformed parts by the expanding material
• CPC Class Codes: B29C 44/186 Filling multiple cavities B29C44/181, B29C44/182 and B29C44/188 takes precedence
• CPC Class Codes: B29K 2995/0002 insulating
• CPC Class Codes: B29L 2031/776 Walls, e.g. building panels
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/732 Dimensional properties
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof
• CPC Class Codes: B32B 2439/00 Containers; Receptacles
• CPC Class Codes: B32B 2479/00 Furniture
• CPC Class Codes: B32B 2509/00 Household appliances
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/20 foamed in situ
• CPC Class Codes: E04C 2/365 by honeycomb structures
• CPC Class Codes: Y02T 50/40 : Weight reduction
• CPC Class Codes: Y10T 428/24157 : Filled honeycomb cells [e.g., solid substance in cavities, etc.]

Abstract

A panel structure and a method of forming the panel structure are disclosed. The panel structure typically includes at least one panel associated with a material. The panel structure has been found particularly advantageous for use as an interior panel of an airplane.

Claims

1. An interior panel structure of a transportation vehicle, comprising:

a first panel formed at least partially of a plastic material;

a second panel formed at least partially of a porous material, the second panel being an outer panel that is closer to a body of the transportation vehicle than the first panel while the first panel is closer to an interior cabin of the transportation vehicle; and

an activatable material intermediate the first panel and the second panel, the activatable material softens, expands, and cures upon exposure to heat;

wherein a volume is defined between the first panel and the second panel and wherein the activatable material when activated, fills from about 5% to about 90% of the volume, and

wherein the interior panel structure, when assembled and in use, provides at least one functional attribute selected from reinforcement, baffling, sound absorption, sound attenuation, baffling or sealing.

2. The interior panel structure as in claim 1, wherein the transportation vehicle is an airplane and the body of the transportation vehicle is a fuselage of the airplane.

3. The interior panel structure as in claim 1, wherein the activatable material is part of a composite that includes a support having a plurality of openings.

4. The interior panel structure as in claim 1, wherein the activatable material is epoxy-based.

5. The interior panel structure as in claim 1, wherein the activatable material is a thermoset, a thermoplastic or a combination thereof.

6. The interior panel structure as in claim 1, wherein the activatable material is adhered to either the first panel or the second panel.

7. The interior panel structure as in claim 1, wherein the first panel is formed of an epoxy/glass composite.

8. The interior panel structure as in claim 1, wherein space is formed between the activatable material when activated and the first panel.

9. The interior panel structure as in claim 3, wherein the support is a honeycomb structure located between the first and second panel.

10. The interior panel structure as in claim 9, wherein expansion of the activatable material provides adhesion between at least one of the panels and the support.

11. The interior panel structure as in claim 1, wherein the activatable material when activated has a compressive strength of about 1.5 MPa or greater.

12. A method of forming an interior panel structure of a transportation vehicle, comprising:

providing a first panel formed at least partially of a plastic material, the first panel being an inner panel at least partially defining an interior cabin of the transportation vehicle;

providing a second panel formed at least partially of a porous material, the second panel being an outer panel that is closer to a body of the transportation vehicle than the first panel;

locating an activatable material that softens, expands, and cures upon exposure to heat and a support intermediate the first panel and the second panel; and

exposing the activatable material to an elevated temperature for activating the activatable material to expand and form a foam whereby the interior panel structure, when assembled and in use, provides a functional attribute selected from reinforcement, baffling, sound absorption, sound attenuation, baffling or sealing to the panel structure,

wherein a volume is defined between the first panel and the second panel and wherein the activatable material when activated, fills from about 5% to about 90% of the volume.

13. The method as in claim 12, wherein a volume is defined between the first panel and the second panel and wherein the foam, the support or both fill at least about 15% of the volume but less than about 75% of the volume.

14. The method as in claim 12, wherein the first panel is formed of an epoxy/glass composite.

15. The method as in claim 12, wherein, upon expansion, the activatable material expands to a volume that is at least 500% greater than its original unexpanded volume.

16. The method as in claim 12, wherein the support is a honeycomb structure located between the first and second panel having a plurality of openings for receiving the activatable material.

17. The method as in claim 16, wherein a plurality of spaces are formed between the foam in each of the plurality of openings and the first panel.

18. The method as in claim 12, wherein a plurality of spaces are formed between the activatable material when activated and the first panel.

19. The method as in claim 12, wherein expansion of the activatable material provides adhesion between at least one of the panels and the support.