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 structured-core laminate panel with sufficient structural properties for use as a building component, comprising:
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, anda 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.