STRUCTURED-CORE LAMINATE PANELS AND METHODS OF FORMING THE SAME
First Claim
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.
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Accused Products
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).
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Citations
20 Claims
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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:
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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. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A structured-core laminate panel with sufficient structural properties for use as a building component, comprising:
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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. - View Dependent Claims (12, 13, 14, 15, 16, 17)
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18. A panel system configured for use as a partition that provides both light transmission and privacy, comprising:
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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. - View Dependent Claims (19, 20)
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Specification