NL2021949B1 - Method for producing a layered panel and layered panel - Google Patents

Method for producing a layered panel and layered panel Download PDF

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Publication number
NL2021949B1
NL2021949B1 NL2021949A NL2021949A NL2021949B1 NL 2021949 B1 NL2021949 B1 NL 2021949B1 NL 2021949 A NL2021949 A NL 2021949A NL 2021949 A NL2021949 A NL 2021949A NL 2021949 B1 NL2021949 B1 NL 2021949B1
Authority
NL
Netherlands
Prior art keywords
layer
outer layer
spacer block
panel according
laminated panel
Prior art date
Application number
NL2021949A
Other languages
Dutch (nl)
Inventor
Albert De Mol Henricus
Bernard Henry Baptist Van Der Wielen Paul
Original Assignee
Tabb Interior Systems B V
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tabb Interior Systems B V filed Critical Tabb Interior Systems B V
Priority to NL2021949A priority Critical patent/NL2021949B1/en
Application granted granted Critical
Publication of NL2021949B1 publication Critical patent/NL2021949B1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/043—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/046—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/12—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/061—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/065—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
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    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/18—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by an internal layer formed of separate pieces of material which are juxtaposed side-by-side
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1284—Application of adhesive
    • B32B37/1292—Application of adhesive selectively, e.g. in stripes, in patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/142—Laminating of sheets, panels or inserts, e.g. stiffeners, by wrapping in at least one outer layer, or inserting into a preformed pocket
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/146—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers whereby one or more of the layers is a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B32B7/14—Interconnection of layers using interposed adhesives or interposed materials with bonding properties applied in spaced arrangements, e.g. in stripes
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B9/047—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material made of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
    • E04C2/365—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels by honeycomb structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2305/34—Inserts

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  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

The present invention relates to a method for producing a layered panel, wherein on a first outer layer at least one spacer block is placed with and an intermediate double sided adhesive tape and a cell structured intermediate layer is placed 5 adjoining the at least one spacer block. Subsequently a second outer layer is placed on top – again including adhesive tape between the second outer layer and the spacer block after which a pressure is exerted on the stack and the double sided adhesive tapes in the stack is heated. The invention also provides a layered panel as produced with this method. 10

Description

Method for producing a layered panel and layered panel
The present invention relates to a method for producing a layered panel and to a layered panel produced with such a method.
Panels used in high-end applications may be engineered to fit the demands relating the specific panel application and/or use. Some examples of high-end panel applications are: interior panels used in mobile applications like means of transport (trains, airplanes, boats, busses, trucks, cars, etc.), furniture panels, interior and exterior construction panels, display panels, screening/partition/shielding panels, construction panels and so on. Demands in such high-end panel applications may be: flexibility in design (in relation to shape, size, thickness, material choices, look, feel and/or additional functionality integration), high strength, low weight, prepared fixation feasibilities; temperature resistancy, fire resistancy, chemical resistancy and/or carrying capacity. To provide many of such demands layered panels are applied in various structures and compositions, wherein different material layers are combined to meet - as much as possible - the demands. The prior art techniques of constructing high-end multi-layered panels are time consuming, expensive, difficult to scale and/or difficult to control in quality.
The present invention has for its object to provide an alternative method for producing a high-end layered panel that is simpler to execute and better to control than the prior art layered panel production methods. It is also an object of the invention to provide a layered panel produced with the method of the present invention of high quality and of which such high quality is controlled and thus may be guaranteed.
To realise these objects the present invention provides a method for producing a layered panel, comprising the processing steps: A) customising a first and a second outer layer at specified shape and dimensions; B) placing the first outer layer in a substantially horizontal position; C) placing at least one spacer block on the internal side of the first outer layer with and an intermediate double sided adhesive tape between at least the spacer block and the first outer layer; D) placing a cell structured intermediate layer at the internal side of the first outer layer, adjoining the at least one spacer block; and E) placing the internal side of the second outer layer on the at least one spacer block and the cell structured intermediate layer that are carried by the first outer layer with and an intermediate double sided adhesive tape between at least the spacer block and the second outer layer; and F) exerting a pressure on a stack of the first outer layer, the double sided adhesive tape, the cell structured intermediate layer and at least one spacer block, the double sided adhesive tape and the second outer layer; wherein the double sided adhesive tapes in the stack are heated to a temperature of at least 50°C. Wirth this method the layered panel is assembled and “glued” together which eliminates the need to use mechanical fasteners, and thus the drawbacks of mechanical fasteners may be avoided (some examples of such draw backs that may be prevented by eliminating mechanical fasteners that they could be are disruptive in appearance, disruptive in strength, disruptive in gas/liquid-tightness, time consuming in applying, adding additional unwanted materials to panel, weakening the construction and so on). However the present invention allows the use of one or more additional mechanical fasteners if such is desirable for a specific panel application. Thus joining the various material by using adhesives, and more specific double sided adhesive tape, enables the provide levelled smooth surfaced panels with solid bounded layers.
The use of double sided adhesive tape, like for instance double-sided acrylic foam tapes, makes it possible to create quick and easy high-strength and long-lasting bonds that also may be resilient. The double sided adhesive tape also enables to join a variety of materials including aluminium, steel, glass, plastics and painted and powder-coated surfaces. A further advantage of the method according to the present invention is that the use of double sided adhesive tape automatically controls the quantity of adhesive used, as the quantity is dictated by the tape. Quality loss due to using too much or too little adhesive will not easy occur and thus the quality of the panel is more in control. The double sided adhesive tape and more in particular the double-sided acrylic foam tape - is normally pressure sensitive and requires substantive pressure (in the order of >5 N/cm2 or >10 N/cm2) to realise a solid bonding. The present invention however, due to the fact that the double sided adhesive tape in the stack is heated to a temperature of at least 50°C, or preferably even a bit warmer to at least 55°C, 60°C or 65°C, makes it superfluous to subject to double sided adhesive tape to this level of pressure. The heat will enhance the fluidity of the adhesive (it enables a flow of the adhesive) so that is binds without the need of a substantial external binding force. The only pressure required during processing step F) to bring the stack layers in contact with each other may be substantive lower (in the order of <5 N/cm2, <3 N/cm2, or even <1N/cm2). The binding of the adhesive tape will normally build strength over time.
As it is possible to produce a panel with only a single spacer block normally a panel will be build incorporating plural spacer blocks. In case these spacer blocks have an identical height (thickness) it enables the production of panels with well controlled parallel first and second outer layers.
The at least one double sided adhesive tape may be attached at the internal side of the first and the second outer layer before the first and/or second outer layer is placed against the at least one spacer block. Preparing the first and/or second outer layer with the adhesive tape before stacking the layers makes it possible to limit the lead time of the method for layered panel producing and also allows to better control the fixation of the adhesive tape onto the first and/or second outer layer. It is also noted that the adhesive tape may only be applied there where a spacer block is to be attached, but as an alternative the adhesive tape may also be applied on a wider area so that also the cell structured intermediate layer partly of fully comes in contact with the adhesive tape. In case the first and/or second outer layer are covered over a full side with adhesive tape the adhesive preparation of the first and/or second outer layer may even be independent of the end product (panel) to be produced.
The (limited) pressure to be exerted on the stack of the first outer layer, the double sided adhesive tape, the cell structured intermediate layer and at least one spacer block, the double sided adhesive tape and the second outer layer may be provided by moving the stack through a press. As already mentioned before the pressure to bring the stack layers in contact with each other may be limited, as long as it ensures a good contact between the layers. Especially when the cell structured intermediate layer is a bit higher (wider) than one or more of the spacer blocks the pressure to be exerted on the stack is to compress (squeeze) cell structured intermediate layer to the same height as the spacer block(s). The press for bringing the stack layers in contact with each other may simultaneously with the pressing process be used for heating the stack; thus combining two processing steps.
To enhance the quality of the attachment of the adhesive tape to an outer layer and/or spacer block the outer layer and/or spacer block may be pre-treated with a primer. Such treatment preferable takes place before the double sided adhesive tape is attached to the outer layer and/or spacer block. An example of a prime to be used is 3M primer 94 ©.
The cell structured intermediate layer placed between the internal sides of the first and second outer layers has - before a pressure is exerted on the stack of layers according to processing step F) - a height that is equally to or higher than the height of the at least one spacer block. This enables the first and second outer layer to clamp the cell structured intermediate layer in between these outer layers when the pressure is exerted on the stack so that a good contact between the first and second outer layer and the cell structured intermediate layer is guaranteed. An even further improvement is realised if the cell structured intermediate layer is adhered to the first and/or second outer layer, for instance - but not limited to only this option - if a double sided adhesive tape is also located in between the cell structured intermediate layer and the first and/or second outer layer.
The invention also provides a layered panel as produced with the method according to the present invention that has been clarified above. For the advantages of this layered panel reference is made to the advantages already mentioned above in relation to the layered panel production method according to the present invention. The layered panel is simple in construction, has a high degree of freedom in design, may be light and strong and has a high quality that is well to control.
The at least one spacer block may be made out of a metal, for instance an aluminium, however also other materials as for instance an (engineering) plastic material could be used as material. Normally a spacer block will be made out of a solid material that has fixed dimensions and is easy to operate. Furthermore it is advantageous if the material of the spacer block is easy to be used for interaction with the outside world (like for fastening the panel of for fastening external elements to the panel (like door handles, hinges, locks, rebates, slots, luminaires and so on).
The at least one spacer block may be longitudinal and or may also coincide with the contour of at least the first or second outer layer. Any shape or size of a spacer block is allowable. If the circumference (outline, periphery) of a panel is partly of completely formed by one or more spacer blocks the interior of the panel (the cell structured intermediate layer) is fully of partly shielded off from the outside wold.
Good strong panel constructions may be realised when a double sided adhesive acrylic foam tape, for instance a VHB-tape™, is used. Such tapes are off the shelf available and thus easy and cheap to obtain.
The panels according to the present invention may have various shapes and dimensions. In the more standard versions of the panels the first and second outer layer have identical shapes and/or dimensions. In this standard embodiment the spacer blocks in the panel have identical heights and the first and second outer layer of the stack are parallel, normally flat. However the present invention also allows the panels to have any spatial structure desired, like for instance curved shapes. Advantageously the cell structured intermediate layer placed between the internal sides of the first and second outer layers is clamped between the first and second outer layer, thus locking the intermediate layer completely between the outer layers. Likewise it is also advantageous if the cell structured intermediate layer completely fills the space between the first and second outer layers left free by the at least one spacer block. The cell structured intermediate layer may be a honeycomb structured layer, preferably a metal honeycomb structured layer or a phenol impregnated paper honeycomb structured layer, as such layers have positive characteristics in weight, strength and thermic insulation value. The cell structured intermediate layer may also be embodied as a fiberglass layer.
As for one or both of the outer layers, these may be embodied as single metal layer, coated metal layer, glass layer, plastic layer, stone layer or multi-layered product containing plural of these material layers.
The present invention will be further elucidated on the basis of the non-limitative exemplary embodiments shown in the following figures. Herein shows:
figure 1 a schematic perspective view on a multi-layered panel according to the present invention;
figures 2 a schematic exploded perspective view on the multi-layered panel as shown in figure 1;
figures 3A - 3F subsequent productions step of the method for producing a layered panel according to the present invention;
figure 4 a perspective view on an alternative embodiment on a multi-layered panel according to the present invention; and figure 5 a perspective view on an further alternative embodiment on a multilayered panel according to the present invention.
Figure 1 shows a panel 1, for instance to be used in the interior of a train, having an front outer layer 2 that is glued onto four spacer blocks 3, 4, 5, 6, on the back side of which spacer blocks 3, 4, 5, 6 a back outer layer 7 is glued. In between the front and back outer layers 2, 7 and the spacer blocks 3, 4, 5, 6 a cell structured intermediate layer 8 is housed. This cell structured intermediate layer 8 may also be glued to the front and/or back outer layers 2, 7. One of the spacer blocks 3 and a part of the front outer layer 2 are machined (e.g. milled) so that an opening 9 remains to accommodate a hinge part (not shown here). Another spacer block 4 is located at a position where holes 10 are drilled (drilled both in the front panel 2 and the spacer block 4) to accommodate fasteners, for instance screws, for the attachment of an item (also not shown here) to the front outer layer 2. A the spacer block 5 is reinforcing a corner 11 of the panel 2 and is also provided with holes 12 on the side of the panel 1. The fourth spacer block 6 is reinforcing another corner 13 of the panel 1.
Figure 2 shows the panel 1 from figure 1 but now in an exploded view and before holes are drilled in the spacer blocks 4, 5 and the front outer layer 2 and before an opening is milled in the spacer block 3 and the front outer layer 2. The spacer blocks 3, 4, 5, 6 are placed on the back outer layer 7 with double sided adhesive tape 20, 21,22, 23, 24 between the spacer blocks 3, 4, 5, 6 and the back outer layer 7. An additional spacer block 25 - that was not visible in figure 1, is formin9 a boundary on one of the sides of the panel 1, thus partially confining the cell structured intermediate layer 8. In this picture the intermediate layer 8 is embodied as a single material piece, however it is also possible to embody the intermediate layer 8 from several separate parts. Clearly visible is that apertures 26, 27, 28, 29 are left open in the intermediate layer 8 to accommodate the spacer blocks 3, 4, 5,
6. The back outer layer 7 here is only adjacent the locations where the spacer blocks 3, 4, 5, 6 are placed provided with double sided adhesive tape 20, 21,22, 23, 24 that also connects to the cell structured intermediate layer 8, however as an alternative also a larger part - or even the complete surface - of the back outer layer 7 may be covered with double sided adhesive tape. Also on the side of the front outer layer 2 that is face to the cell structured intermediate layer 8 double sided adhesive tape will be provided (that is not visible in this picture), at least at the locations where the spacer blocks 3, 4, 5, 6 will contact the front outer layer 2.
In figures 3A - 3F subsequent productions step of the method for producing a layered panel 30 according to the present invention are shown. In figure 3A a first outer layer 31 that has been brought in the desired shape and dimensions is shown and in figure 3B a double sided adhesive tape 32 is attached to this first outer layer
31. In the subsequent process step spacer blocks 33, 34 are placed on the first outer layer 31. In figure 3D also a cell structured intermediate layer 35 is placed on the first outer layer 31, filling the space left between the spacer blocks 33, 34. As shown here the thickness of the cell structured intermediate layer 35 is larger than the thickness of the spacer blocks 33, 34. In figure 3E a second outer layer 36 that is provided with double sided adhesive tape 37 on the side facing the spacer blocks 33, 34 and the cell structured intermediate layer 35 - is pressed (see arrows Pi) onto the first outer layer 31 with the spacer blocks 33, 34 and the cell structured intermediate layer 35. Also visible is that the higher cell structured intermediate layer 35 is now compressed to a thickness according the thickness of the spacer blocks 33, 34. In figure 3F the complete panel 30 is now heated 38 so that the double sided adhesive tapes 32, 37 reach a temperature that enhances the fluidity of the adhesive on the adhesive tapes 32, 37 so to create a substantial bounding between the various components of the panel 30 without the need of applying the substantial pressure normally required to realise such bonding.
Figure 4 shows a panel 40 according to the present invention, with an upper outer layer 41, various spacer blocks 42, an intermediate cell structured layer 43 and a lower outer layer 44. Different form the panels 1, 30 shown in the previous figures this panel 40 has a curved shape.
In figure 5 a panel 50 is shown that is prepared as a door panel. The whole circumference of the door panel 50 is provided with spacer blocks 51,52, 53, 54 (here thus spacer beams) as is represented also with a dashed line. At the location where a door handle has to applied a larger spacer block 55 is located and an opening 56 for the attachment of a door handle housing has already been provided (e.g. milled). The same applies for the locations where hinges will be attached. Also here wider spacer blocks 57, 58, 59 are located and also here apertures 60, 61,62 for the hinge attachment are visible. More central in the door panel 50 a window opening 63 is left open of which the boundary is also fully covered with spacer blocks 64, 65. Again a dashed line represents the location where spacer blocks around the window opening 63 are located.

Claims (20)

1. Werkwijze voor het produceren van een gelaagd paneel, omvattende de processtappen:A method for producing a laminated panel, comprising the process steps: A) het aanpassen van een eerste en een tweede buitenste laag aan gespecificeerde vorm en dimensies;A) adapting a first and a second outer layer to specified shape and dimensions; B) het plaatsen van de eerste buitenste laag in een in hoofdzaak horizontale positie;B) placing the first outer layer in a substantially horizontal position; C) het plaatsen van ten minste één afstandhouderblok aan de binnenzijde van de eerste buitenste laag met een tussenliggende dubbelzijdige plakband tussen ten minste het afstandhouderblok en de eerste buitenste laag;C) placing at least one spacer block on the inside of the first outer layer with an intermediate double-sided adhesive tape between at least the spacer block and the first outer layer; D) het plaatsen van een celgestructureerde tussenlaag aan de binnenzijde van de eerste buitenste laag, grenzend aan het ten minste ene afstandhouderblok; enD) placing a cell-structured intermediate layer on the inside of the first outer layer adjacent to the at least one spacer block; and E) het plaatsen van de binnenzijde van de tweede buitenste laag op het ten minste ene afstandhouderblok en de celgestructureerde tussenlaag die door de eerste buitenste laag worden gedragen, met een tussenliggend dubbelzijdig plakband tussen ten minste het afstandhouderblok en de tweede buitenste laag; enE) placing the inner side of the second outer layer on the at least one spacer block and the cell-structured intermediate layer carried by the first outer layer, with an intermediate double-sided tape between at least the spacer block and the second outer layer; and F) het uitoefenen van een druk op een stapeling van de eerste buitenste laag, het dubbelzijdige plakband, de celgestructureerde tussenlaag en ten minste één afstandhouderblok, het dubbelzijdige plakband en de tweede buitenste laag;F) applying pressure to a stack of the first outer layer, the double-sided adhesive tape, the cell-structured intermediate layer and at least one spacer block, the double-sided adhesive tape and the second outer layer; waarbij de dubbelzijdige plakbanden in de stapeling worden verwarmd tot een temperatuur van ten minste 50°C.wherein the double-sided adhesive tapes are heated in the stack to a temperature of at least 50 ° C. 2. Werkwijze voor het produceren van een gelaagd paneel volgens conclusieA method of producing a laminated panel according to claim 1, met het kenmerk dat het ten minste ene dubbelzijdige plakband aan de binnenzijde van de eerste en de tweede buitenste laag wordt gehecht, voordat de eerste of tweede buitenste laag tegen het ten minste ene afstandhouderblok wordt geplaatst.1, characterized in that the at least one double-sided adhesive tape is adhered to the inside of the first and the second outermost layer before the first or second outermost layer is placed against the at least one spacer block. 3. Werkwijze voor het produceren van een gelaagd paneel volgens conclusie 1 of 2, met het kenmerk dat er druk op de stapeling van de eerste buitenste laag, het dubbelzijdige plakband, de celgestructureerde tussenlaag en ten minste één afstandhouderblok, het dubbelzijdige plakband en de tweede buitenste laag wordt uitgeoefend door het door een pers bewegen van de stapeling.A method of producing a laminated panel according to claim 1 or 2, characterized in that there is pressure on the stacking of the first outer layer, the double-sided adhesive tape, the cell-structured intermediate layer and at least one spacer block, the double-sided adhesive tape and the second outer layer is applied by moving the stack through a press. 4. Werkwijze voor het produceren van een gelaagd paneel volgens conclusieA method of producing a laminated panel according to claim 3, met het kenmerk dat de pers die druk op de stapeling uitoefent eveneens de stapeling verwarmt.3, characterized in that the press applying pressure to the stack also heats the stack. 5. Werkwijze voor het produceren van een gelaagd paneel volgens één van de eerdere conclusies, met het kenmerk dat, voordat het dubbelzijdige plakband aan een buitenste laag en/of afstandhouderblok wordt bevestigd, de buitenste laag en/of het afstandhouderblok met een primer wordt voorbehandeld.Method for producing a laminated panel according to any one of the preceding claims, characterized in that before the double-sided adhesive tape is attached to an outer layer and / or spacer block, the outer layer and / or the spacer block is pretreated with a primer . 6. Werkwijze voor het produceren van een gelaagd paneel volgens één van de eerdere conclusies, met het kenmerk dat de tussen de binnenzijden van de eerste en tweede buitenste laag geplaatste celgestructureerde tussenlaag een hoogte heeft die even hoog of hoger is dan de hoogte van het ten minste ene afstandhouderblok en dat door het uitoefenen van een druk op de stapeling de celgestructureerde tussenlaag tussen de eerste en tweede buitenste laag wordt geklemd.Method for producing a laminated panel according to any one of the preceding claims, characterized in that the cell-structured intermediate layer placed between the inner sides of the first and second outer layer has a height equal to or higher than the height of the at least one spacer block and that the cell-structured intermediate layer is clamped between the first and second outer layers by applying pressure on the stack. 7. Werkwijze voor het produceren van een gelaagd paneel volgens één van de eerdere conclusies, met het kenmerk dat de celgestructureerde tussenlaag aan de eerste en/of tweede buitenste laag is gehecht.A method of producing a laminated panel according to any one of the preceding claims, characterized in that the cell-structured intermediate layer is adhered to the first and / or second outer layer. 8. Gelaagd paneel zoals geproduceerd met de werkwijze volgens één van de eerdere conclusies.Laminated panel as produced by the method according to any of the previous claims. 9. Gelaagd paneel volgens conclusie 8, met het kenmerk dat het ten minste ene afstandhouderblok een metalen blok, bijvoorbeeld een aluminiumblok is.Laminated panel according to claim 8, characterized in that the at least one spacer block is a metal block, for example an aluminum block. 10. Gelaagd paneel volgens conclusie 8 of 9, met het kenmerk dat het ten minste ene afstandhouderblok langgerekt is.Laminated panel according to claim 8 or 9, characterized in that the at least one spacer block is elongated. 11. Gelaagd paneel volgens één van de conclusies 8 tot en met 10, met het kenmerk dat het ten minste ene afstandhouderblok samenvalt met de contour van ten minste de eerste of tweede buitenste laag.Laminated panel according to any one of claims 8 to 10, characterized in that the at least one spacer block coincides with the contour of at least the first or second outer layer. 12. Gelaagd paneel volgens één van de conclusies 8 tot en met 11, met het kenmerk dat het dubbelzijdige plakband een dubbelzijdig plakband van acrylschuim, bijvoorbeeld een VHB-tape™ is.Laminated panel according to any one of claims 8 to 11, characterized in that the double-sided adhesive tape is a double-sided adhesive tape made of acrylic foam, for example a VHB-tape ™. 13. Gelaagd paneel volgens één van de conclusies 8 tot en met 12, met het kenmerk dat de eerste en tweede buitenste laag identieke vormen en/of dimensies hebben.Laminated panel according to any one of claims 8 to 12, characterized in that the first and second outer layers have identical shapes and / or dimensions. 14. Gelaagd paneel volgens één van de conclusies 8 tot en met 13, met het kenmerk dat, wanneer er meer dan één afstandhouderblok in het paneel is geïntegreerd, alle afstandhouderblokken identieke hoogtes hebben.Laminated panel according to any one of claims 8 to 13, characterized in that when more than one spacer block is integrated in the panel, all spacer blocks have identical heights. 15. Gelaagd paneel volgens één van de conclusies 8 tot en met 14, met het kenmerk dat de eerste en tweede buitenste laag van de stapeling evenwijdig zijn.Laminated panel according to any one of claims 8 to 14, characterized in that the first and second outer layers of the stack are parallel. 16. Gelaagd paneel volgens één van de conclusies 8 tot en met 15, met het kenmerk dat de tussen de binnenzijden van de eerste en tweede buitenste laag geplaatste celgestructureerde tussenlaag tussen de eerste en tweede buitenste laag is geklemd.Laminated panel according to any one of claims 8 to 15, characterized in that the cell-structured intermediate layer placed between the inner sides of the first and second outer layer is clamped between the first and second outer layer. 17. Gelaagd paneel volgens één van de conclusies 8 tot en met 16, met het kenmerk dat de celgestructureerde tussenlaag een laag met honingraatstructuur is, bij voorkeur een metaallaag met honingraatstructuur of een met fenol geïmpregneerde papierlaag met honingraatstructuur.Laminated panel according to any one of claims 8 to 16, characterized in that the cell-structured intermediate layer is a layer with a honeycomb structure, preferably a metal layer with a honeycomb structure or a phenol-impregnated paper layer with a honeycomb structure. 18. Gelaagd paneel volgens één van de conclusies 8 tot en met 17, met het kenmerk dat de celgestructureerde tussenlaag een vezelglaslaag is.Laminated panel according to any one of claims 8 to 17, characterized in that the cell-structured intermediate layer is a fiber glass layer. 19. Gelaagd paneel volgens één van de conclusies 8 tot en met 18, met het kenmerk dat de eerste en/of tweede buitenste laag een enkele metaallaag is, een gecoate metaallaag, een glaslaag, een kunststof laag, een steenlaag of een meerlaagsproduct omvattende meerdere van deze materiaallagen.Laminated panel according to any one of claims 8 to 18, characterized in that the first and / or second outer layer is a single metal layer, a coated metal layer, a glass layer, a plastic layer, a stone layer or a multilayer product comprising several of these material layers. 20. Gelaagd paneel volgens één van de conclusies 8 tot en met 19, met hetLaminated panel according to any of claims 8 to 19, including the 5 kenmerk dat de celgestructureerde tussenlaag de volledige ruimte tussen de eerste en tweede buitenste laag vult, die door het ten minste ene afstandhouderblok is vrijgelaten.5 characterized in that the cell-structured intermediate layer fills the entire space between the first and second outer layers, which is left free by the at least one spacer block.
NL2021949A 2018-11-07 2018-11-07 Method for producing a layered panel and layered panel NL2021949B1 (en)

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US20070207305A1 (en) * 2006-03-06 2007-09-06 York International Corporation Panel construction for an air handling unit
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US20150268009A1 (en) * 2013-01-16 2015-09-24 Hardwire, Llc Vehicular Armor System

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