Panel structure

• US 20060000186A1
• Filed: 06/14/2005
• Published: 01/05/2006
• Est. Priority Date: 06/18/2004
• Status: Active Grant

• Current Assignee: Zephyros, Inc.
• Original Assignee: L&L Products Inc.
• Inventors: Harthcock, Matthew, Carlson, David, Walker, Jason, Madaus, Brandon, Taylor, C. L. Jr., Barton, Kearney
• Granted Patent: US 8,070,994 B2
• Time in Patent Office: Days
• US Class Current: 52/793.100
• 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 walls, panels B32B2607/00
• CPC Class Codes: B32B 2439/00 Containers; Receptacles closures therefor B32B2435/00
• CPC Class Codes: B32B 2479/00 Furniture upholstery B32B2601/00
• 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. 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;

providing a second panel, the second panel being an outer panel that is closer to the body of the transportation vehicle than the first panel while the first panel is closer to an interior cabin of the transportation vehicle; and

disposing a material intermediate the first panel and the second panel, the material including at least one functional attribute selected from reinforcement, baffling, sound absorption, sound attenuation, baffling or sealing.

2. A method as in claim 1 wherein the transportation vehicle is an airplane and the body of the transportation vehicle is the fuselage of the airplane.

3. A method as in claim 1 wherein the material is part of a composite that includes a support having a plurality of openings.

4. A method as in claim 1 wherein the material is epoxy-based.

5. A method as in claim 1 wherein the material is activatable to soften, expand and cure upon exposure to heat.

6. A method as in claim 1 wherein the material is a thermoset, a thermoplastic or a combination thereof.

7. A method as in claim 1 wherein the material is adhered to the both the first panel and the second panel.

8. A method as in claim 1 wherein a layer of adhesive adheres the material to the first panel.

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

providing a first panel, 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 fabric material, the second panel being an outer panel that is closer to the body of the transportation vehicle than the first panel;

locating an expandable material and a support intermediate the first panel and the second panel; and

exposing the expandable material to an elevated temperature for activating the expandable material to expand and form a foam whereby the foam provides a functional attribute selected from reinforcement, baffling, sound absorption, sound attenuation, baffling or sealing to the panel structure.

10. A method as in claim 9 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.

11. A method as in claim 9 wherein the first panel is formed of an epoxy/glass composite.

12. A method as in claim 9 wherein, upon expansion, the expandable material expands to a volume that is at least 500% greater than its original unexpanded volume.

13. A method as in claim 9 wherein the support is a honeycomb structure and the foam defines a relatively high strength regions suitable for providing strength at an attachment region of the panel structure.

14. 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 fabric material that includes a metal, the second panel being an outer panel that is closer to the body of the transportation vehicle than the first panel; and

locating an expandable material and a support intermediate the first panel and the second panel;

exposing the expandable material to an elevated temperature for activating the expandable material to expand and form a foam whereby the foam is located in a relatively high strength region of the panel structure and the foam has a compressive strength of at least about 1.5 MPa; and

assembling the panel structure to the interior of an aircraft.

15. A method as in claim 14 wherein the high strength region is a peripheral region that at least partially defines a relatively large opening that has a volume greater than about 4 cm³ and a component extends through the relatively large opening upon assembly of the panel structure to the aircraft.

16. A method as in claim 14 wherein a component is attached to the high strength region.

17. A method as in claim 14 wherein the panel structure includes a secondary foam adjacent the foam of the high strength region and wherein the secondary foam has a compressive strength than is less that the compressive strength of the foam of the peripheral region.

18. A method as in claim 17 wherein the secondary foam has a compressive strength that is less than about 90% of the compressive strength of the foam of the peripheral region.

19. A method as in claim 18 wherein a volume is defined between the first panel and the second and wherein the secondary foam, the support or both fill at least about 15% of the volume but less than about 75% of the volume.

20. A method as in claim 14 wherein the high strength region is a peripheral region extends from an edge at least 1 cm into the panel structure and the first foam substantially fills the peripheral region and the support is a honeycomb structure.