US20100252195A1 - Methodology for creating layered panel structure including self-bonded thermoformable and non-thermoformable layer materials - Google Patents
Methodology for creating layered panel structure including self-bonded thermoformable and non-thermoformable layer materials Download PDFInfo
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- US20100252195A1 US20100252195A1 US12/802,693 US80269310A US2010252195A1 US 20100252195 A1 US20100252195 A1 US 20100252195A1 US 80269310 A US80269310 A US 80269310A US 2010252195 A1 US2010252195 A1 US 2010252195A1
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- thermoformable
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/02—Physical, chemical or physicochemical properties
- B32B7/027—Thermal properties
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24149—Honeycomb-like
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
- Y10T428/2495—Thickness [relative or absolute]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
- Y10T428/24992—Density or compression of components
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
- Y10T428/249942—Fibers are aligned substantially parallel
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
- Y10T428/249942—Fibers are aligned substantially parallel
- Y10T428/249947—Polymeric fiber
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
- Y10T428/31645—Next to addition polymer from unsaturated monomers
Abstract
A method of forming a layered, generally planar panel structure including the steps of (a) utilizing applied heat and pressure, causing a melt of resin present in a thermoformable material layer to flow toward and into an adjacent non-thermoformable material layer, and (b) by such utilizing and causing, forming a thermal-compression, mechanical, inter-material-transition bond between the layers.
Description
- This application is a continuation from currently copending U.S. patent application Ser. No. 11/881,907, filed Jul. 30, 2007, for “Layered Panel Structure Including Self-Bonded Thermoformable and Non-Thermoformable Layer Materials”, which application claims filing date priority to U.S. Provisional Patent Application Ser. No. 60/835,313, filed Aug. 2, 2006 for “Thermoform Layered Structure and Method”. The entire disclosure contents of these two, prior-filed applications are hereby incorporated herein by reference.
- The present invention relates to methodology for creating a thermo-compression-formed, layered panel structure, and in particular, for creating such a structure which features a special assembly of both thermoformable and non-thermoformable layer materials self-bondedly joined through what is referred to herein as being a differentiated-material, transition-discontinuity-style, thermally bonded interface, or thermal bond (also called a thermal-compression mechanical bond).
- According to this invention, a generally planar, layered panel structure is created which, while, as just mentioned, being generally planar in nature, may have certain topographical surface features that may, at least partially, be compression-thermoformed during assembly of the layer materials which make up the panel structure. The panel structure produced by practice of the invention features a relatively low-density, low-cost, non-thermoformable, principal, generally planar body having opposite faces, to at least one of which faces is thermally compressively bonded to a face in a higher-density, typically-higher-cost, much thinner, fibre-strand-reinforced, thermoformable plastic skin. The body, as measured transversely between its opposite faces (its transfacial thickness), is thicker than the skin as also so measured.
- The thermal compression, or thermal compressive, bond existing between these thermoformable and non-thermoformable materials, as created in the panel structure of the invention, is referred to variously herein as a self-bond to reflect the fact that, preferably, no additional bonding adhesive is employed. Rather molten plastic material from the thermoformable material per se flows to create the uniting bond between the materials, and a consequence of this structural bonding arrangement is that a finished panel structure performs throughout with just the two desired structural characteristics of only the selected thermoformable and non-thermoformable materials. This has proven, in many application settings, to be a functionally desirable characteristic of the structure created by the invention, in that the inter-material, transition bond region per se does not exhibit the otherwise expectable, and perhaps somewhat unpredictable, load-managing behavior of a foreign bonding substance.
- This layered assembly, i.e., the panel structure produced by the methodology of the present invention, possesses useful overall dimensional bulk (i.e., mainly thickness) which is contributed chiefly by the transfacial thickness of the lower-density body (layer), along with elevated load-bearing strength which is furnished principally by the appreciably higher-density (to be discussed later herein), significantly thinner, strand-reinforced skin (layer). This skin, in addition to offering elevated load-bearing strength, as just mentioned, also affords a high degree of abrasion resistance.
- These two different-thermal-characteristic materials may be surface-joined in different organizational ways in an overall panel structure made in accordance with the present invention. Two such surface joined ways are specifically illustrated herein, including one wherein a finished panel structure is formed with just one-each layer of each of these two materials, and another wherein there is, in a finished panel structure, a central, or core, layer formed of the non-thermoformable material, united with a pair of opposite-side-cladding skin layers formed of the thermoformable material.
- The self-bond union of these two materials, produced via a thermally compressively bonded interface described herein, as mentioned above, as being a differentiated-material, transition-discontinuity-style interface, produces a composite structural panel assembly which exhibits (a) the strength that one would typically and intuitively associate with a unitary, homogeneous structure having the thickness and bulk of the principal, non-thermoformable body material, and (b) the light-weightness that one would typically and intuitively associate with a unitary, homogeneous structure having the thinness and low, apparent bulk of the thermoformable skin material. These “intuitive” associations, of course, would most probably come about, at least in part, because of a lack of an initial understanding of the appreciably different layer-density and internal-strength characteristics that are correctly associated with the two different materials that have been chosen for use in the panel structure created by the invention.
- Additionally, thermoformability of the skin, and thermal bonding of the skin to the body, uniquely allow for the fabrication, in several different ways, of a structural panel having, if desired, a complex surface topography (a) dictated by either or both of (1) pre-shaping of the bonding face of the non-thermoformable body, and/or (2) modest thermal-deformation-compression of the thermoformable skin material, and/or (3) a combination of these two approaches. Where body-material pre-shaping is employed, such pre-shaping telegraphs easily into the final panel configuration of the skin because of the skin's naturally offered thermo-configurational-deformability that is enabled and invoked during thermal-compression bonding of the body and the skin.
- Many applications exist for the structural panel produced by this invention, including within-building wall and door applications, such as garage-door and hurricane-door-and window-panel applications, truck and trailer bed applications, vehicle door-panel applications, boating-structure applications, and many others.
- These and other features which are offered by the layered, composite panel structure which results from practice of the present invention will become more fully apparent as the description of the invention which shortly follows this text, is read in conjunction with the accompanying drawings.
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FIG. 1 is a fragmentary, schematic, cross-sectional view of one embodiment of a panel structure made in accordance with practice of the present invention, which panel structure includes a principal body layer made of low-density, non-thermoformable material, to one face in which there is thermally, compressively bonded a fibre-strand-reinforced, higher-density, thermoformable plastic skin layer. -
FIG. 2 is a larger-scale, fragmentary, schematic plan illustration of an arrangement of reinforcing fibres included within the skin layer mentioned inFIG. 1 , which fibres are deployed in a non-woven, substantially orthogonal pattern with respect to one another. -
FIG. 3 is similar toFIG. 2 , except that this figure illustrates reinforcing fibres which are unidirectional and substantially parallel to one another in the mentioned skin layer. -
FIG. 4 is similar toFIG. 1 , except that it illustrates a modified form of panel structure made in accordance with implementation of the present invention wherein the generally planar principal body layer has thermally and compressively bonded to each of its two, opposite, broad, generally planar faces a skin layer of the type mentioned in relation toFIG. 1 . -
FIG. 5 is a fragmentary illustration, similar to a portion ofFIG. 1 , showing a surface topographical feature which has been created in a region of the illustrated surfacing skin layer by deformation-compression of the skin-layer material during thermal-bonding of the skin layer to the principal body layer. -
FIG. 6 is somewhat similar toFIG. 5 , except thatFIG. 6 shows surface topographical features that have resulted from pre-surface shaping of one of the faces of the illustrated non-thermoformable principal body layer, which shaping telegraphs through to the overall surface of the panel structure through the thermally bonded, thermoformable surfacing skin layer. Such telegraphing takes place during bonding of the skin layer to the principal body layer.FIG. 6 also illustrates a surface topographic feature which has been created in the manner of the topographic feature pictured inFIG. 5 . -
FIG. 7 illustrates another modified panel form created by practice of the invention in which, on the outer surface of the illustrated skin layer, an auxiliary surfacing material, such as a decorative patterning material, has been attached to the skin layer by thermal-bonding. - Turning attention now to the drawings, and referring first of all to
FIGS. 1-3 , inclusive, indicated generally at 10 inFIG. 1 is a fragmentary, schematic cross-sectional view of a generally planar, layered panel structure made in accordance with a preferred manner of practicing the present invention.Structure 10 includes a principal body layer, or body layer portion, 12 which has a thickness T herein, also referred to as a transfacial thickness, of about 3/4-inches, and which formed of a suitable low-density, light-weight, relatively low-cost, non-thermoformable material, such as balsa wood. Such wood has a density d typically of about 7-lbs/ft3. - Other satisfactorily usable principal body materials include PVC foam, urethane foam, honeycomb plastics, honeycomb metals and corrugated wood. The preferred density (d) range for a chosen principal body material herein is about 4-lbs/ft3 to about 30-lbs/ft3.
- Thermally compressively bonded to the
upper surface 12 a ofbody 12 inFIG. 1 , through what is referred to herein as the earlier-mentioned differentiated-material, transition-discontinuity-style bonded interface, which interface is shown by a darkened and thickenedline 14 inFIG. 1 , is a fibre-strand-reinforced, thermoformable plastic resin skin, or skin layer, 16 (reinforcing strands, or fibres, embedded within thermoformable resin). Preferably,skin 16 is formed as a thermally bonded/integrated plurality of three, stacked, generally planar sub-layers, such as the three sub-layers schematically shown at 16 a inFIG. 1 , which sub-layers are formed each of individually fibre-strand-reinforced, thermoformable, plastic-resin material in sheet form. Each of these three sub-layer sheets has a transfacial thickness At lying in the range of about 0.015- to about 0.020-inches, with the stacked collection of all three of these sub-layers thus having a collective transfacial thickness t lying in the range of about 0.045- to about 0.060-inches. Inpanel structure 10, each of sub-layer sheets 16 a preferably has a thickness of about 0.016-inches, and the overall transfacial thickness ofskin layer 16 therefore has a transfacial thickness of about 0.048-inches. - The plastic resin material in
skin layer 16, illustrated generally at 16 b, is substantially continuous and homogeneous because of the thermoforming procedure which has been used to formpanel structure 10. This thermoforming procedure causes a resin melt and flow to occur withinlayer 16, and this melt and flow create the homogeneity characteristic just described. It should be understood that, while horizontal sub-layer division lines appear inFIG. 1 (and in two other drawing figures herein), these lines have been included just to clarify visually the presences of three sub-layer sheets used in the formation ofpanel structure 10. - The reinforcing fibre strands in
skin layer 16, represented generally by dashed lines 16 c, lie (float) essentially in three, spaced, substantially parallel planes indicated at 17 inFIG. 1 . - Turning attention for a moment to
FIGS. 2 and 3 , and understanding that each of sub-layers is essentially the same in internal construction,FIG. 2 illustrates, for one of sub-layers 16 a, a preferred organization of therein-embedded strands 16 c, with these strands being non-woven, and, as just above suggested, “floating” within the sub-layer with generally orthogonal dispositions relative to one another inresin 16 b. InFIG. 3 , strands 16 c in the sub-layers are generally unidirectional and parallel one another. - Not specifically illustrated in the drawings, but understood to be a possible organization within the skin sub-layers, is an organization wherein the reinforcing strands are woven in a mesh form. Also not specifically shown, it will be understood that sub-layers 16 a may be stacked so as to have their included reinforcing strands, from a sub-layer to sub-layer point of view, oriented at angles relative to one another. Further, there may be applications wherein it is desirable to use a greater or lesser number of sub-layers than three.
- While many different specific skin materials may be used appropriately in the structure created by the present invention, preferably the thermoformable resin which is employed in this skin material—a thermoplastic resin—is selected from the group including polypropylene, polyester, polyethylene and the material known as PET, and preferably is chosen to be a polypropylene resin, such as that which is employed in a commercial product sold under the trademark Polystrand® made by a company of that same name, located in Montrose, Calif. This preferred-resin skin material has a density D of about 130-lbs/ft3. The fibre reinforcing strands embedded within the skin-material resin are preferably selected from the group including glass, E-glass, S-glass and carbon fibre, and from this group, are preferably made of S-glass.
- Within the skin material per se, it is preferable that the ratio, by weight, of strand material to resin lie in the range of about 60:40 to about 80:20, and a preferred ratio is 70:30. With such a preferred ratio, the density D of the preferred polypropylene skin material is, as was mentioned above, about 130-lbs/ft3. Additionally, it is preferred that an appropriate thermoforming temperature for the chosen resin, i.e., a suitable melt/flow temperature therefore, be about 340° F. This thermoforming temperature is what is associated with
preferred polypropylene resin 16 b herein. - In accordance with the invention, with the principal body and
skin materials panel structure 10, as shown inFIG. 1 , is formed from a layer stack of these two materials by compressively thermally bondingskin 16 tosurface 12 a inbody 12 utilizing the appropriate thermal-bonding temperature associated with the particular resin employed in the skin material. An appropriate bonding application pressure of about 30-psi is employed, and when this is done at the appropriate temperature,interface bond 14 is formed by a melt and flow of the skin-material resin material into engagement withbody surface 12 a andbody 12. Wherebody 12 is formed of a material such as balsa wood, resin melt from the skin material usually enters the pores within such body material. This interfacial resin melt is what directly formsinterface bond 14, and is why this bond is referred to herein as a “self-bond”. - What results in this procedure is a panel structure (10) having all of the important lightweightness and strength features set forth earlier herein. Appropriate panel bulk is furnished chiefly by the principal body material included in
structure 10, and appropriate rigidity and load-bearing strength are contributed principally by the fibre-reinforced thermally-bonded surfacing skin layer.Interface bond 14, formed as it is by resin material melt and flow coming from the skin material during thermal compressive bonding, contributes to such load-bearing strength. - A modified layer form producible by the invention is illustrated in
FIG. 4 . Shown here, and employing substantially the same reference numerals utilized so far herein inFIG. 1 , a modifiedpanel structure 18 is formed having aprincipal body 12 which is thermally joined, in addition to a thermally-bondedskin 16 onbody surface 12 a, to a companion and like surfacingskin 20 that is similarly thermally bonded to the opposite face 12 b inbody 12. - One of the interesting features uniquely accommodated by the panel structure created by the methodology of the present invention, because of the thermoformable nature of the surfacing skin material which is employed, is illustrated in several different versions in
FIGS. 5 and 6 in the drawings. Specifically, these two drawing figures illustrate the possibility of forming subtle, and even complex, three dimensional surface topography features in the outwardly facing surface of the surfacing skin material layer employed in a produced panel structure. - In
FIG. 5 asingular surface depression 16A is illustrated inskin layer 16, this depression, which exists only inlayer 16, having been formed principally by deformation-compression oflayer 16 during thermal-bonding of the assembled panel-structure materials. Topographic shaping, as is here shown, may be accomplished by the use of an external device, such as a heated platen having the appropriate, complementary surface shape. With cooling after such a procedure, the surface ofskin layer 16, as shown inFIG. 5 takes on with permanence the formeddepression 16A. - In
FIG. 6 , pre-shaping in the surface topography ofsurface 12 a inpanel body 12 has taken place to create a pair of stepped depressions 12A, 12B. This kind of body-surface shaping may, of course, be performed in any appropriate manner. During thermal-bonding ofskin 16 tobody 12, the thermoformable nature of the skin allows it, through what is referred to herein as telegraphing, to take on with great precision, the pre-shaped topography formed in the underlying body-layer surface (seedepressions 16B, 16C which “follow” depressions 12A, 12B, respectively). - It is of course possible to create even more complicated surface topographies through utilizing a combination of the surface shaping approaches so far discussed, respectively, with respect to in
FIGS. 5 and 6 . For example,FIG. 6 shows, at 16D, 16E, two other kinds of depression-character surface topography which illustrate a certain quality of obtainable surface topographic complexity. - Finally,
FIG. 7 illustrates yet a further modified panel-structure form creatable by the invention, which form may be chosen for use in certain applications. This modification includes the thermal-bonding, to the outside surface of a skin layer, such asskin layer 16, of some form of appropriate “other” surfacing material, such as the layer material shown generally at 22 inFIG. 7 . This other surfacing material (22) is bonded toskin layer 16 during thermal-bonding ofskin layer 16 toprincipal body layer 12, with the bond which thus develops between the skin layer and the added surfacing material developing through contact of that added material with thermally melted resin coming from the skin layer resin. - Thus, production of a special composite panel structure has been shown and described herein in both preferred and modified forms with this resulting panel structure featuring the union, in different ways, of both thermoformable and non-thermoformable materials having the relative density and transfacial thickness characteristics mentioned above herein. The union of these two materials opens the door for the creation of a relatively wide-ranging family of generally planar panel structures which may be employed successfully in a number of applications, such as the several applications mentioned earlier herein. The load-bearing characteristic of the panel structure made in accordance with the present invention, with respect to the thermal bond which exists at a transition interface region between thermoformable and non-thermoformable materials relies entirely upon bonding between these materials which is achieved during thermoforming by a melt and flow of the resin employed in the thermoformable material. Accordingly, no additional adhesive material is employed and, as was also mentioned earlier herein, uncertainties about the load-bearing characteristics of such additional material play no role in the consideration of the design of a panel structure made in accordance with practice of the invention the invention.
- By various techniques and user choices, interesting and even quite complex surface topographies can be created in the manner generally described above, and a consequence of this is that a panel structure made according to the practice of the invention may be designed to fit in a number of different applications where surface topographical features are desired for various reasons.
- Accordingly, while preferred and modified manners of practicing, and embodiments of, the invention have been illustrated and described herein, it is appreciated that variations and modifications may be made without departing from the spirit of the invention, and it is intended that all such variations and modifications will come within the scope of the claims to invention presented herein.
Claims (3)
1. A method of forming a layered, generally planar panel structure comprising
providing a non-thermoformable core layer having opposite sides,
placing adjacent and against one side of the core layer a fibre-reinforced, resin-based, thermoformable layer to create, in combination with the core layer, a layer stack,
applying heat and pressure to the layer stack, and
by said applying, causing a melt of resin in the thermoformable layer, and a resulting flow of such melted resin toward and into the non-thermoformable layer, thus to form a thermal-compression, mechanical, inter-material-transition bond between the layers.
2. A method of forming a layered, generally planar panel structure comprising
placing adjacent and against one of the two, opposites sides of a non-thermoformable material layer a fibre-reinforced, resin-based, thermoformable material layer to create a stack from the two layers,
applying heat and pressure to the stack, and
by said applying, causing a melt of resin in the thermoformable material layer, and a resulting flow of such melted resin toward and into the non-thermoformable material layer, thus to form a thermal-compression, mechanical, inter-material-transition bond between the layers.
3. A method of forming a layered, generally planar panel structure comprising
utilizing applied heat and pressure, causing a melt of resin present in a thermoformable material layer to flow toward and into an adjacent non-thermoformable material layer, and
by said utilizing and causing, forming a thermal-compression, mechanical, inter-material-transition bond between the layers.
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US12/802,693 US20100252195A1 (en) | 2006-08-02 | 2010-06-11 | Methodology for creating layered panel structure including self-bonded thermoformable and non-thermoformable layer materials |
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US83531306P | 2006-08-02 | 2006-08-02 | |
US11/881,907 US7790274B2 (en) | 2006-08-02 | 2007-07-30 | Layered panel structure including self-bonded thermoformable and non-thermoformable layer materials |
US12/802,693 US20100252195A1 (en) | 2006-08-02 | 2010-06-11 | Methodology for creating layered panel structure including self-bonded thermoformable and non-thermoformable layer materials |
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US11/881,907 Division US7790274B2 (en) | 2006-08-02 | 2007-07-30 | Layered panel structure including self-bonded thermoformable and non-thermoformable layer materials |
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US11/881,907 Expired - Fee Related US7790274B2 (en) | 2006-08-02 | 2007-07-30 | Layered panel structure including self-bonded thermoformable and non-thermoformable layer materials |
US12/802,679 Expired - Fee Related US7943232B2 (en) | 2006-08-02 | 2010-06-11 | Layered panel structure including self-bonded layers of thermoformable and non-thermoformable materials |
US12/802,693 Abandoned US20100252195A1 (en) | 2006-08-02 | 2010-06-11 | Methodology for creating layered panel structure including self-bonded thermoformable and non-thermoformable layer materials |
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US11/881,907 Expired - Fee Related US7790274B2 (en) | 2006-08-02 | 2007-07-30 | Layered panel structure including self-bonded thermoformable and non-thermoformable layer materials |
US12/802,679 Expired - Fee Related US7943232B2 (en) | 2006-08-02 | 2010-06-11 | Layered panel structure including self-bonded layers of thermoformable and non-thermoformable materials |
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WO2013086021A1 (en) * | 2011-12-06 | 2013-06-13 | 3M Innovative Properties Company | Monolithic multilayer article |
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US7790274B2 (en) * | 2006-08-02 | 2010-09-07 | High Impact Technology, Llc | Layered panel structure including self-bonded thermoformable and non-thermoformable layer materials |
US7798548B2 (en) * | 2007-01-03 | 2010-09-21 | Gm Global Technology Operations, Inc. | Soft composite trim panel for a vehicle interior |
US20080166526A1 (en) * | 2007-01-08 | 2008-07-10 | Monk Russell A | Formed panel structure |
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---|---|---|---|---|
WO2013086021A1 (en) * | 2011-12-06 | 2013-06-13 | 3M Innovative Properties Company | Monolithic multilayer article |
CN104053547A (en) * | 2011-12-06 | 2014-09-17 | 3M创新有限公司 | Monolithic multilayer article |
Also Published As
Publication number | Publication date |
---|---|
US20080032102A1 (en) | 2008-02-07 |
WO2008016668A2 (en) | 2008-02-07 |
US20100255283A1 (en) | 2010-10-07 |
WO2008016668A3 (en) | 2008-07-03 |
US7790274B2 (en) | 2010-09-07 |
US7943232B2 (en) | 2011-05-17 |
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