Panel structure

• US 9,688,050 B2
• Filed: 11/09/2011
• Issued: 06/27/2017
• Est. Priority Date: 06/18/2004
• Status: Active Grant

• Current Assignee: Zephyros, Inc.
• Original Assignee: Zephyros, Inc.
• Inventors: Carlson, David, Madaus, Brandon, Barton, Kearney, Taylor, Charles L., Harthcock, Matthew, Walker, Jason
• Primary Examiner(s): Grun, Robert J
• Application Number:
  US13/292,686
• Publication Number:
  US 20120048451A1
• Time in Patent Office: 2,057 Days
• Field of Search: 264 465
• 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 woven prepreg thermoset material that cures when exposed to temperatures above 230°

F.;

a second panel formed at least partially of a porous material that allows sound waves to pass through the second panel, 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

a heat-activated foamable elastomeric material intermediate the first panel and the second panel, the elastomeric material foaming at temperatures above 230°

F. and whereby after expansion the elastomeric material is a foam material that wets and bonds to one or more adjacent surfaces;

wherein space is formed between the foam material and the first panel; and

wherein the panel structure, when assembled and in use, provides sound absorption, damping, or attenuation by virtue of the sound waves passing through pores of the porous material of the second panel and into the foam material and the space between the foam material and the first panel.

2. A 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. A panel structure as in claim 1, wherein a honeycomb structure is located between the first panel and second panel and receives the elastomeric material, the honeycomb structure including a plurality of openings.

4. A panel structure as in claim 3, wherein the elastomeric material adheres the honeycomb structure to only one of the first panel and second panel.

5. A panel structure as in claim 3, wherein the elastomeric material adheres the honeycomb structure to the first panel upon foaming.

6. A panel structure as in claim 1, wherein the panel structure is adapted for being located in a heat press so that the woven prepreg thermoset material cures and the elastomeric material foams.

7. A panel structure as in claim 5, wherein no further adhesive is used to bond the elastomeric material to the first panel and the honeycomb structure.

8. A panel structure as in claim 1, wherein the first panel is formed of an epoxy/glass composite.

9. A panel structure as in claim 1, wherein the panel structure is assembled prior to foaming of the elastomeric material.

10. A panel structure as in claim 3, wherein a plurality of spaces are formed between the foam material in each of the plurality of openings and the first panel so that sound becomes absorbed into the plurality of spaces.

11. A panel structure as in claim 3, wherein the elastomeric material is located as a continuous layer in between the honeycomb structure and the first panel.

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

a first panel formed at least partially of a woven prepreg thermoset material that cures when exposed to temperatures above 230°

F.;

a second panel formed at least partially of a porous material that allows sound waves to pass through the second panel, 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

a heat-activated foamable elastomeric material intermediate the first panel and the second panel, the elastomeric material foaming at temperatures above 230°

F. and whereby after expansion the elastomeric material is a foam material that wets and bonds to one or more adjacent surfaces;

a honeycomb structure located between the first panel and second panel and including a plurality of openings for receiving the elastomeric material;

wherein the foam material and voids or cells defined by the foam material post-cure fills from about 5% to about 90% of each of the plurality of openings so that a plurality of spaces are formed between the foam material in each of the plurality of openings and the first panel so that sound becomes absorbed into the plurality of spaces.

13. A panel structure as in claim 12, wherein the elastomeric material adheres the honeycomb structure to only one of the first panel and second panel.

14. A panel structure as in claim 12, wherein the elastomeric material adheres the honeycomb structure to the second panel upon foaming.

15. A panel structure as in claim 12, wherein the panel structure is adapted for being located in a heat press so that the woven prepreg thermoset material cures and the elastomeric material foams.

16. A panel structure as in claim 14, wherein no further adhesive is used to bond the elastomeric material to the second panel and the honeycomb structure.

17. A panel structure as in claim 12, wherein the first panel is formed of an epoxy/glass composite.

18. A panel structure as in claim 12, wherein the panel structure is assembled prior to foaming of the elastomeric material.