Structured-core laminate panels and methods of forming the same

Abstract

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).

We claim: 
     
         1 . A method of manufacturing a translucent, structured-core laminate panel in a manner that substantially resists delamination, and without use of an adhesive film, comprising:
 preparing a laminate assembly comprising one or more resin substrates having a first glass transition temperature positioned about a structured core having a second melt or glass transition temperature, wherein the first glass transition temperature is lower than the second melt or glass transition temperature;   heating the laminate assembly to a processing temperature at least as great as the first glass transition temperature but below the second melt or glass transition temperature, wherein a portion of the one or more resin substrates flows into the structured core; and   cooling the laminate assembly below the first glass transition temperature to create a unitary structured-core laminate panel;   wherein the one or more resin substrates bond to the structured core without substantial deformation of the structured core.   
     
     
         2 . The method as recited in  claim 1 , wherein the processing temperature is between about 180° F. and about 275° F., and the method further comprises subjecting the laminate assembly to a processing pressure of about 40 psi. 
     
     
         3 . The method as recited in  claim 1 , wherein:
 the structured-core comprises a honeycomb matrix with a plurality of structured chambers made substantially of polycarbonate or mixtures thereof, and   the one or more resin substrates comprise a sheet of copolyester, acrylic, or mixtures thereof.   
     
     
         4 . The method as recited in  claim 1 , further comprising positioning a colored film against at least one of the one or more resin substrates. 
     
     
         5 . The method as recited in  claim 4 , further comprising positioning an additional resin substrate against the colored film opposite the at least one of the one or more resin substrates. 
     
     
         6 . The method as recited in  claim 4 , wherein each of the one or more resin substrates, the structured core, and color film are thermoformed together in a single step. 
     
     
         7 . The method as recited in  claim 1 , further comprising positioning the laminate assembly into a vacuum bag, wherein the laminate assembly is heated and/or pressurized in a vacuum press or autoclave. 
     
     
         8 . The method as recited in  claim 1 , wherein the structured core comprises a plurality of cylinder-shaped cells having openings at a first end and an opposing second end. 
     
     
         9 . The method as recited in  claim 8 , further comprising:
 positioning a first surface of a first translucent resin substrate and a second surface of a second translucent resin substrate in substantially perpendicular orientations relative to the cylinder-shaped cells;   wherein the first surface covers the openings of the first end of the plurality cylinder-shaped cells, and the second surface covers the openings of the second end of the plurality cylinder-shaped cells.   
     
     
         10 . A structured-core laminate panel prepared in accordance with the process recited in  claim 1 . 
     
     
         11 . 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, and 
 a 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. 
   
     
     
         12 . The structured-core laminate panel as recited in  claim 11 , further comprising a colored film fused to a second surface of the at least one resin substrate opposite the first surface. 
     
     
         13 . The structured-core laminate panel as recited in  claim 12 , further comprising:
 an additional resin substrate fused to the colored film;   wherein the colored film is positioned between the at least one substrate and the additional substrate.   
     
     
         14 . The structured-core laminate panel as recited in  claim 11 , wherein the at least one structured-core comprises polycarbonate and the at least one resin substrate comprises a translucent copolyester. 
     
     
         15 . The structured-core laminate panel as recited in  claim 11 , wherein the plurality of cells of the at least one structured-core comprise honeycomb cells. 
     
     
         16 . The structured-core laminate panel as recited in  claim 11 , wherein the plurality of cells of the at least one structured-core comprise cylindrical-shaped cells oriented perpendicularly to the first surface of the at least one resin substrate. 
     
     
         17 . The structured-core laminate panel as recited in  claim 11 , wherein the plurality of cells comprise cells having at least three different sizes. 
     
     
         18 . A panel system configured for use as a partition that provides both light transmission and privacy, comprising:
 one or more translucent structured-core laminate panels, comprising:
 one or more resin substrates having a first glass transition temperature, and 
 one or more structured cores including a plurality of cells, 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 resin substrates extend into and are fused to the plurality of cells of the one or more structured cores; and 
   a mounting system that secures to the one or more translucent structured-core laminate panels to a support structure.   
     
     
         19 . The panel system as recited in  claim 18 , wherein the mounting system comprises hardware that supports the one or more translucent structured-core laminate panels as a sliding door. 
     
     
         20 . The panel system as recited in  claim 18 , wherein the mounting system comprises hardware that supports the one or more translucent structured-core laminate panels as one or more of a ceiling, floor, wall, or partition.