Methods and apparatus to couple a decorative layer to a core layer of a panel via a barrier layer

Abstract

Methods and apparatus to couple a decorative layer to a core layer of a panel via a barrier layer are disclosed. An example apparatus includes a decorative layer coupled to a panel. The panel has a core layer. The example apparatus includes a barrier layer disposed between the core layer and the decorative layer. The barrier layer is to impede at least one of gas or vapor from escaping from the core layer to the decorative layer to deter the at least one of gas or vapor from exerting a pressure on the decorative layer to deter a portion of the decorative layer from separating from the panel.

What is claimed is: 
     
         1 . An apparatus comprising:
 a decorative layer coupled to a panel, the panel having a core layer; and   a barrier layer disposed between the core layer and the decorative layer, the barrier layer to impede at least one of gas or vapor from escaping from the core layer to the decorative layer to deter the at least one of gas or vapor from exerting a pressure on the decorative layer to deter a portion of the decorative layer from separating from the panel.   
     
     
         2 . The apparatus of  claim 1 , wherein the barrier layer is a plastic film that impedes the at least one of gas or vapor from traversing therethrough. 
     
     
         3 . The apparatus of  claim 1 , wherein the decorative layer is coupled to the panel via an adhesive layer. 
     
     
         4 . The apparatus of  claim 1 , wherein the core layer is at least one of a honeycomb layer or a foam core. 
     
     
         5 . The apparatus of  claim 1 , wherein the barrier layer is coupled to a surface of the panel. 
     
     
         6 . The apparatus of  claim 5 , further including a sealing layer that is applied to cover a portion of the barrier layer. 
     
     
         7 . The apparatus of  claim 1 , wherein the panel includes an outer layer, and wherein the barrier layer is between the core layer and the outer layer. 
     
     
         8 . The apparatus of  claim 1 , wherein the panel includes:
 a first reinforcing layer coupled to the core layer, the first reinforcing layer including a first fiber reinforcing layer and a first resin layer;   the barrier layer coupled to the first reinforcing layer that is coupled to the core layer; and   a second reinforcing layer coupled to the barrier layer that is coupled to the first reinforcing layer, the second reinforcing layer including a second fiber reinforcing layer and a second resin layer.   
     
     
         9 . The apparatus of  claim 8 , wherein at least one of the first reinforcing layer or the second reinforcing layer is a pre-impregnated layer. 
     
     
         10 . The apparatus of  claim 1 , wherein the panel includes the core layer and a first reinforcing layer coupled to the core layer, the first reinforcing layer includes:
 a first resin layer;   a fiber reinforcing layer coupled to the first resin layer;   a second resin layer coupled to the fiber reinforcing layer that is coupled to the first resin layer; and   the barrier layer coupled to the second resin layer that is coupled to the fiber reinforcing layer.   
     
     
         11 . The apparatus of  claim 10 , wherein the panel includes a second reinforcing layer coupled to the first reinforcing layer that is coupled to the core layer. 
     
     
         12 . An apparatus comprising:
 means for decorating a panel, the panel having means for providing structure;   means for impeding gas and vapor flow disposed between the means for decorating and the means for providing structure, the means for impeding gas and vapor flow to impede at least one of gas or vapor from escaping from the means for providing structure to the means for decorating to deter the at least one of gas or vapor from exerting a pressure on the means for decorating to deter a portion of the means for decorating from separating from the panel.   
     
     
         13 . The apparatus of  claim 12 , further including means for coupling the means for decorating to the panel. 
     
     
         14 . A method comprising:
 coupling a barrier layer to a core layer of a panel; and   coupling a decorative layer to the barrier layer that is coupled to the core layer, the barrier layer to impede at least one of gas or vapor from escaping from the core layer to the decorative layer to deter the at least one of gas or vapor from exerting a pressure on the decorative layer to deter a portion of the decorative layer from separating from the panel.   
     
     
         15 . The method of  claim 14 , wherein coupling the barrier layer to the core layer includes coupling the barrier layer to a first surface of the panel. 
     
     
         16 . The method of  claim 15 , further including sweeping or sanding the barrier layer coupled to the first surface of the panel to smoothen a second surface of the barrier layer to further deter the at least one of gas or vapor from exerting the pressure on the decorative layer. 
     
     
         17 . The method of  claim 16 , further including applying a sealing layer to cover a portion of the second surface of the barrier layer. 
     
     
         18 . The method of  claim 14 , further including forming the panel by:
 coupling a first reinforcing layer to the core layer;   coupling the barrier layer to the first reinforcing layer that is coupled to the core layer to couple the barrier layer to the core layer; and   coupling a second reinforcing layer to the barrier layer that is coupled to the core layer via the first reinforcing layer.   
     
     
         19 . The method of  claim 14 , further including forming the panel by:
 forming a reinforcing layer that includes the barrier layer and a fiber reinforcing layer; and   coupling the reinforcing layer to the core layer to couple the barrier layer to the core layer.   
     
     
         20 . The method of  claim 19 , wherein forming the reinforcing layer includes:
 coupling a fiber reinforcing layer to a first resin layer;   coupling a second resin layer to the fiber reinforcing layer that is coupled to the first resin layer; and   coupling the barrier layer to the second resin layer that is coupled to the fiber reinforcing layer.