Structured-core laminate panels and methods of forming the same

摘要

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).

主权项

1. A panel system configured for use as a partition that provides both light transmission and privacy while displaying a structured core through one or more transparent resin substrates, comprising:
one or more first translucent structured-core laminate panels, comprising:
one or more first thermoplastic, transparent resin substrates having a first glass transition temperature, andone or more structured cores including a plurality of hollow chambers, 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 first thermoplastic, translucent resin substrates has flowed into the hollow chambers, such that the one or more first thermoplastic, transparent resin substrates is deformed and extends into, and is mechanically attached to, the plurality of hollow chambers of the one or more structured cores without any intervening adhesive film layer, and without any deformation of the structured core; wherein the plurality of hollow chambers of the one or more structured cores is displayed through the one or more transparent resin substrates without any dimpling or deformation caused by deformation with the structured core on the opposing side; and a mounting system that secures the one or more translucent structured-core laminate panels to a support structure.