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 translucent structured-core laminate panel with sufficient structural properties for use as a building component, comprising:
at least one resin substrate, wherein the at least one resin substrate comprises a transparent thermoplastic resin sheet having a first glass transition temperature; and at least one structured-core laminated and mechanically bonded directly to a first surface of the at least one resin substrate, the at least one structured-core comprising a plurality of cells; with hollow chambers wherein:
the at least one structured core has a second melt or glass transition temperature that is higher than the first glass transition temperature;a portion of the at least one resin substrate positioned directly against the at least one structured core has flowed into the hollow chambers of the plurality of cells, such that the at least one structure core is fused to, extends into, and is mechanically interlocked with the plurality of cells of the at least one structured core; andthe at least one resin substrate provides both a direct bond to the at least one structured core on one side while maintaining a substantially planar outer surface to the structured core on an opposing side.