NL2028452B1 - Reinforced multi-layered panel and method for producing such a reinforced multi-layered panel - Google Patents

Reinforced multi-layered panel and method for producing such a reinforced multi-layered panel Download PDF

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Publication number
NL2028452B1
NL2028452B1 NL2028452A NL2028452A NL2028452B1 NL 2028452 B1 NL2028452 B1 NL 2028452B1 NL 2028452 A NL2028452 A NL 2028452A NL 2028452 A NL2028452 A NL 2028452A NL 2028452 B1 NL2028452 B1 NL 2028452B1
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Netherlands
Prior art keywords
layer
panel
outer panel
layers
cell
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Application number
NL2028452A
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Dutch (nl)
Inventor
Albert De Mol Henricus
Original Assignee
Tabb Interior Systems B V
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Priority to NL2028452A priority Critical patent/NL2028452B1/en
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Publication of NL2028452B1 publication Critical patent/NL2028452B1/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
    • B32B15/046—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
    • 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
    • B32B27/065—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 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
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • 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
    • B32B3/04—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 at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
    • 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
    • B32B3/12—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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • 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
    • 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
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • 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
    • B32B9/046—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 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
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/028—Paper 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0285—Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • 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
    • B32B2479/00—Furniture
    • 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
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars
    • 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
    • B32B2605/00—Vehicles
    • B32B2605/10—Trains
    • 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
    • B32B2605/00—Vehicles
    • B32B2605/12—Ships
    • 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
    • B32B2605/00—Vehicles
    • B32B2605/18—Aircraft
    • 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
    • B32B2607/00—Walls, panels

Landscapes

  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

The present invention relates to a multi-layered panel, having first and second opposite outer panel layers with at least one of the panel layers having a 5 longitudinal side with a raised edge; a cell structured intermediate layer located between the panel layers, with the raised edge directed towards the opposite panel; an adhesive material connecting the cell structured intermediate layer with the outer panel layers, and a cured filling material arranged adjacent the raised edge. The invention also relates to a method for producing such a multi-layered panel.

Description

Reinforced multi-layered panel and method for producing such a reinforced multi-layered panel The present invention relates to a reinforced multi-layered panel and to a method for producing such a reinforced multi-layered panel. 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 present invention has for its object to provide an improved type high-end multi- layered panel that combines the mechanical and physical properties of existing high-end multi-layered panels like for instance the high-end multi-layered panels as disclosed in the Dutch patent 2021949 of the present applicant, but that has enhanced mechanical properties that facilitate a firm fixation of objects in and on the panel. It is also an object of the invention to provide a method for producing such a reinforced multi-layered panel that requires only limited amendment of the existing production methods and that is relatively simple to perform.
To realise these objects the present invention provides a multi-layered panel, comprising: first and second opposite outer panel layers at specified shape and dimensions with at least one of the panel layers having at least one longitudinal side with a raised edge; a cell structured intermediate layer located between the internal sides of the outer panel layers, with the at least one raised edge of at least one of the panel layers directed towards the opposite panel; an adhesive material connecting the cell structured intermediate layer directly with the outer panel layers,
and a cured filling material arranged in at least a space between the panel parts adjacent to at least one raised edge.
The multi-layered panel according the present invention combines a large freedom of form/shape with a great stiffness.
As the multi-layered panel is “glued” together the need to use mechanical fasteners is eliminated, and it is advantageous that the cell structured intermediate layer is directly connected with the outer panel layers; this limits the use of components (intermediate fleece/web/film layers are superfluous) and makes the production process relative simple, fast, solid and cheap.
For a closed execution of a front side at least one of the panel layers had at least one longitudinal side with a raised edge.
Such a raised edge, or edges, provide a flat and neat finish of one or more of the end faces of the layered panel, but it also adds to the stiffness of the multilayer panel according to the present invention.
The cell structured intermediate layer may continue until the raised edge but it will be inevitable that some cells of the intermediate layer will be damaged (open). Also in practise it will be difficult to have a perfect joining of the cell structured intermediate layer and a (or all) raised edge(s) leading to locally some broader or smaller opening between the cell structured intermediate layer and the raised edge(s). This may lead to lesser properties of the multi-layered panel as for instance it is sensible for the entrance of pollution.
It is therefore advantageous to arrange a cured filling material in at least a space between the panel parts adjacent to at least one raised edge.
The filling material is normally initially — when brought at the desired location - in a fluid state and de raised edge will prevent the filling material to flow away before it is cured.
The cured filling material may prevent the entrance of pollution in the multi-layered panel of the present invention but may also provide an improved insulation value of the multi-layered panel.
As will be clarified later in more detail; the cured filling material may be useful for a better fixation of insets in the multi-layered panel.
The at least one raised edge may be embodied as a bended raised edge.
Bending, or so called “setting” or “folding”, is a processing technique in which an angle is set in (metal) sheet.
Bending is an efficient process to realise raised edge.
For instance when and edge has to be provided with a 90° corner to the panel surface the edge may be bended a bit more than the 90° so that after the partial rebound of the converted part an angle of 90° remains.
In an embodiment at least one of the panel layers is bounded by (only) straight sides and all sides have raised edges protruding in the same direction such that the raised edges are forming a protruding continuous ridge. Preferably in such embodiment (all) adjoining raised edges are close fitting. With such an embodiment the panel layer with the protruding continuous ridge maybe seen as a low bin, which construction will prevent the filling material - in it starting fluid state - to flow out of the raised edge. Also the continuous raised edge has the advantage that the complete circumference of the multi-layered panel is shielded with a raised circumferential edge.
A further advantage of the cured filling material adjoining at least one raised edge of the multi-layered panel according to the present invention is that — as mentioned briefly before — that one or more fixing elements may be attached in at least one of the panel layers whereby that insert is at least partly embedded in the cured filling material. The filling material will provide support for a more firm/solid attachment of the insert in the multi-layered panel. Examples of such inserts are potting inserts and helicoils. Such inserts may be used to attach external objects to the multi- layered panel, or vice versa, to attach the multi-layered panel to another object. A helicoil is a threaded insert, for instance to hold an (external) screw and a potting insert are used for, among others, bolting or for form-fit attachment of a multi- layered panel. For relative simple construction and easy assembly in an embodiment only one of the panel layers has a protruding edge and the opposite panel layer is a flat panel layer. This requires only one of the panel layers to be provided with one or more raised edges. As the cured filling material that is adjoining at least one raised edge fills a space between the raised edge and the cell structured intermediate layer also the connection between the raised edge and the cell structured intermediate layer is provided thus further enhancing the structural sturdiness of the multi-layered panel according to the present invention. Preferably the cured filling material adjoining at least one raised edge is also filling atleast a part of the cell structured intermediate layer as this leads to a formfitting connection of the filling material and the cell structured intermediate layer, which again enhances the structural sturdiness of the multi-layered panel according to the present invention.
Advantageous filling materials are modified PU and/or Acrylic glue.
These materials have favourable product features and are not extremely expensive.
In a further advantageous embodiment a pre-foamed phenolic foam may be located in the cells of the cell structured intermediate layer.
The addition of such phenolic foam enhances the thermal insulating properties.
Pre-foamed rigid phenolic insulation products offer very good thermal insulating properties due to the very low thermal conductivity (extreme low A values of 0.018 W/m.K)). Its low thermal conductivity allows specified thermal performance targets to be achieved with minimal thickness of insulation.
Due to the incorporation of the pre-foamed phenolic foam in the cells of the intermediate layer located between the internal sides of the outer panel layers the mechanical strength of the multi-layered panel is not influenced by the inclusion of the phenolic foam.
Furthermore also the fire performance of phenolic foam is exceptional.
It combines zero or very low flame spread with negligible smoke emission and a very low level of toxic gas emission.
Furthermore the phenolic foam is rodent/insect proof, low water absorbent,
corrosion and chemical resistant, it resists organic solvents and chemicals, it is non-abrasive and hydrophobic and it does not corrode metal.
Also the service temperature range of phenolic foam is wide (approximately -200°C - 130°C). Besides the cell structured intermediate layer also at least one spacer block may be located between the internal sides of the outer panel layers.
The presence of the one or more spacer blocks may provide additional functionality to the multi-layered panel.
Not only the distance between the outer layers may be controlled with the presence of at least one spacer block but also the sides of the layers panel may be shielded with one or more spacer blocks and/or the spacer blocks may be used as mechanical stable elements for attaching external objects to the layers panel, like for instance door handles, hinges, fasteners, frames, locks, rebates, slots, luminaires and so on.
If more than one spacer block is integrated in the panel all spacer blocks have identical heights then the multi-layered panel will as a result normally be a flat panel, or in other words, the first and second outer layer are parallel in such situation.
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, 5 strength and thermic insulation value. The cell structured intermediate layer may also be embodied as a fiberglass layer. The adhesive material to be used for connecting the cell structured intermediate layer to the outer panel layers may also connect the at least one spacer block to the internal sides of the outer panel layers. An adhesive material to be used in this application is for instance a polyurethane adhesive like 2KPU. However additionally or as an alternative also a double sided adhesive tape, like for instance double- sided acrylic foam tapes as VHB-tape ™ may also be applied. All the adhesive materials to be selected for use in the layered panel according the present invention have to be able to create quick and easy high-strength and long-lasting bonds that also may be resilient. The adhesive material has to enable to join a variety of materials including aluminium, steel, glass, plastics and painted and powder-coated surfaces. As an alternative or in combination with another adhesive also a double sided adhesive tape may be used.
The layers 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 a standard embodiment the first and second outer layer of the stack are parallel, except for the raised edge(s).
However the present invention also allows the panels to have any spatial structure desired, like for instance curved shapes. As for one or both of the outer panel 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 also provides a method for producing a multi-layered panel according to any of the preceding claims, comprising the processing steps: A) customising a first and a second outer panel layer at specified shape and dimensions; B) providing at least one raised edge on at least on longitudinal side of at least the first panel layer; C) placing the first outer panel layer in a substantially horizontal position; D) placing a cell structured intermediate layer directly at the internal side of the first outer panel layer with an intermediate adhesive material between the first outer panel layer and the cell structured intermediate layer; E) bringing a cureable filling material in at least a space adjoining at least one raised edge; F) placing the internal side of the second outer panel layer directly on cell structured intermediate layer with only an intermediate adhesive material between the cell structured intermediate layer and the second outer panel layer; and G) exerting a pressure on a stack of the first outer panel layer, the adhesive material, the cell structured intermediate layer, the adhesive material and the second outer panel layer. For the advantages of this method for producing a multi-layered panel reference is made to the advantages already mentioned above in relation to the multi-layered panel according to the present invention.
Atleast one fixing element, like a potting insert and/or helicoil, may attached in at least one of the panel layers such that the insert is at least partly embedded in the cured filling material. The fixing element may be attached to the multi-layered panel during any phase of the production process even if the filling material is not cured yet, or even not brought into its position. Only for substantially loading the fixing element (e.g. on traction) it is better to wait until the filling material is substantially, or even better completely, cured.
Before step F) at least one spacer block may be placed on the internal side of the first outer panel layer with an intermediate adhesive material, for instance a double sided adhesive tape, between at least the spacer block and the first outer panel layer while the adhesive material may be attached at the internal side of the first and the second outer panel layer before the first or second outer panel layer is placed against the cell structured intermediate layer. Preparing the first and/or second outer layer with the adhesive material before stacking the layers makes it possible to limit the lead time of the method for multi-layered panel producing and also allows to better control the fixation of the adhesive material onto the first and/or second outer layer. The cell structured intermediate layer may partly of fully come in contact with the adhesive material.
The (limited) pressure to be exerted on the stack of the first outer layer, the adhesive material, the cell structured intermediate layer, the adhesive material 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. 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. During such double action pressing/heating the stack may be heated to a temperature of at least 50°C.
The present invention will be further elucidated on the basis of the non-limitative exemplary embodiments shown in the following figures. Herein shows: figure 1A a schematic perspective view on a multi-layered panel according to the present invention in an initial production state; figure 1B a schematic perspective view on the multi-layered panel according to figure 1A in more assembled but still partially exploded state; figure 1B a schematic perspective view on the multi-layered panel according to figures 1A and 1B in an assembled state including an insert; figure 2A a schematic perspective view on a first outer panel layer with all sides provided with a raised edge forming a protruding continuous ridge; figure 2B a schematic perspective view on the first outer panel layer of figure 2A wherein the first outer panel layer is filled with a cell structured intermediate layer and a cured filling material is arranged adjoining the protruding continuous ridge of the first outer panel layer; figure 2C a schematic perspective view on a multi-layered panel according to the present invention including the first outer panel layer from figures 2A and 2B; figure 3 a schematic perspective view on an alternative embodiment of a multi-layered panel according to the present invention in an exploded view; figures 4A — AG subsequent stages of the method for producing a multi- layered panel according to the present invention; and figures 5A and 5B perspective views on a potting insert and a helicoil that may be inserted in the multi-layered panel according to the present invention.
Figure 1A shows a schematic perspective view on a multi-layered panel 1 in an initial production state. A first outer panel layer 2 has two raised edges 3, 4 on two adjoining longitudinal sides 5, 6. An adhesive material 7 is brought onto the (inner) side of the panel layer 2. Also shown is a cell structured intermediate layer 8 that has to be embedded between the first outer panel layer 2 and a second outer panel layer 9. The cured filling material is not shown in this figure (yet). In figure 1B the multi-layered panel 1 from figure 1A is in a further production phase, wherein the cell structured intermediate layer 8 is assembled with the first outer panel layer 2 and here also a cured filling material 10 is arranged adjacent to the raised edge 3. The cured filling material 10 is partially filling a slit between the cell structured intermediate layer 8 and the raised edge 3 but is also filling some of the open cells of the intermediate layer 8 bordering the raised edge 3 as well as some closed cells close to the raised edge 3. Figure 1C shows the multi-layered panel 1 from figures 1A and 1B in a compete assembled state wherein the second outer panel layer 9 is glued onto the first outer panel layer 2 holing both, the cell structured intermediate layer 8 and the cured filling material 10. In this assembled multi-layered panel 1 also an insert 11 is included at a location where the insert 11 finds support in the cured filling material 10, which this provides an additional structural strength to the attachment of the insert 11. Furthermore the cured filling material 10 seals off an edge part of the multi-layered panel 1.
Figure 2A shows a schematic perspective view on a first outer panel layer 20 of with four straight sides 21, 22, 23, 24 all of which have raised edges 25, 26, 27, 28 protruding in the same direction. The raised edges 25, 26, 27, 28 are forming a protruding continuous ridge. Also reference is made to the fact that adjoining raised edges 25, 26, 27, 28 are close form fitting. Figure 2B shows the first outer panel layer 20 wherein an cell structured intermediate layer 21 is glued. Bordering the adjoining raised edges 25, 26, 27, 28 a filling material 29 is added, normally in a fluid state, and this filling material 29 is hardened such that is shields the inner side of the cell structured intermediate layer
21 and any free openings between the raised edges 25, 26, 27, 28 and the cured filling material 29 is filled. The cured filling material 29 provides advantageous properties to a multi-layered panel 30 (as shown in its complete assembled state in figure 2C). The cured filling material 29 adds strength to the multi-layered panel 30 but also seals off the sides of the multi-layered panel 30.
In figure 3 an alternative embodiment of a multi-layered panel 40 according to the present invention is shown in an exploded view, having upper and lower opposite outer panel layers 41, 42 and a cell structured intermediate layer 43 located between the internal sides of the outer panel layers 41, 42. The internal sides of the outer panel layers 41, 42 are both provided with layers of adhesive material 44, 45. Different from the multi-layered panels, 30 1 as shown in the previous figures here also spacer blocks 46 are placed on the lower outer panel layer 42, or more correct they are placed onto the layer of adhesive material 44 that is attached to the lower outer panel layer 42. After an at least partial assembly of the lower outer panel layers 41, with raised edge 47, a curable filling material may be added from a dosing unit 48. In figures 4A — 4G subsequent productions step of the method for producing a multi-layered panel 50 according to the present invention are shown. In figure 4A a first outer layer 51 is shown that has been brought in the desired dimensions and that is subsequently bended in figure 4B so that it possess at least one raise edge
52. In figure 4C a layer of adhesive material 53 is brought onto this first outer layer
51. In the subsequent process step shown in figure 4D also a cell structured intermediate layer 54 is placed on the first outer layer 51. In figure 4E a filling material 55 is brought between the intermediate cell structured layer 54 and the raised edge 52, as well as in the intermediate cell structured layer 54 close to the raised edge 52. Figure 4F shows that a second outer layer 56 - that is also provided with a layer of adhesive material 57 on the cell structured intermediate layer 54 while exerting pressure and heat. In figure 4G the complete panel 50 is shown including an insert 58, which insert 58 is embedded in the cured filling material 55. Figures 5A and 5B show two fixing element 60, 61, here a potting insert 60 and a helicoil 61, to be inserted in the multi-layered panel according to the present invention.
The potting insert 60 provides a through opening 62 for fixing objects to a multi-layered panel or for fixing the multi-layered panel with the potting insert 60 onto another object.
The helicoil 61 is especially useful for holding a screw of screw fixture.

Claims (21)

ConclusiesConclusions 1. Meerlaags paneel, bestaande uit: - eerste en tweede overliggende buitenste paneellagen met specifieke vorm en afmetingen, waarbij ten minste één van de paneellagen ten minste één langszijde heft met een opstaande rand; - een tussenlaag met celstructuur die zich tussen de binnenzijden van de buitenste paneellagen bevindt, waarbij de ten minste ene opstaande rand van ten minste één van de paneellagen naar het tegenoverliggende paneel is gericht; - een kleefmateriaal dat de celgestructureerde tussenlaag rechtstreeks verbindt met de buitenste paneellagen, en - een uitgehard vulmateriaal aangebracht in ten minste één ruimte tussen de paneeldelen grenzend aan ten minste één opstaande rand.CLAIMS 1. Multi-layer panel, consisting of: - first and second opposing outer panel layers with specific shape and dimensions, wherein at least one of the panel layers has at least one longitudinal side with a raised edge; - a cellular intermediate layer located between the inner sides of the outer panel layers, the at least one raised edge of at least one of the panel layers facing the opposite panel; - an adhesive material directly bonding the cell-structured intermediate layer to the outer panel layers, and - a cured filler material disposed in at least one space between the panel parts adjacent to at least one raised edge. 2. Gelaagd paneel volgens conclusie 1, met het kenmerk, dat ten minste één opstaande rand een omgezette opstaande rand is.2. Laminated panel according to claim 1, characterized in that at least one raised edge is a folded raised edge. 3. Gelaagd paneel volgens conclusie 1 of 2, met het kenmerk, dat ten minste één van de paneellagen wordt begrensd door rechte zijden en alle zijden zijn voorzien van in een zelfde richting uitkragende opstaande randen, zodanig dat de opstaande randen een uitkragende doorlopende rand vormen.3. Laminated panel as claimed in claim 1 or 2, characterized in that at least one of the panel layers is bounded by straight sides and all sides are provided with raised edges protruding in the same direction, such that the raised edges form a protruding continuous edge. . 4. Gelaagd paneel volgens conclusie 3, met het kenmerk, dat aangrenzende opstaande randen nauw op elkaar aansluiten.4. Laminated panel as claimed in claim 3, characterized in that adjacent upright edges fit closely together. 5. Gelaagd paneel volgens een der voorgaande conclusies, met het kenmerk, dat ten minste één bevestigingselement, zoals een pot-inzet ("potting insert”) en/of helicoil, in tenminste één van de paneellagen is aangebracht, zodanig dat het bevestigingselement tenminste gedeeltelijk is ingebed in het uitgeharde vuimateriaal.A laminated panel according to any one of the preceding claims, characterized in that at least one fastening element, such as a potting insert and/or helicoil, is arranged in at least one of the panel layers, such that the fastening element is at least is partially embedded in the cured dirt material. 6. Gelaagd paneel volgens een der voorgaande conclusies, met het kenmerk, dat één van de paneellagen een uitkragende rand heeft en de overliggende paneellaag een vlakke paneellaag is.6. Laminated panel according to any one of the preceding claims, characterized in that one of the panel layers has a protruding edge and the opposite panel layer is a flat panel layer. 7. Gelaagd paneel volgens een der voorgaande conclusies, met het kenmerk, dat het uitgeharde vulmateriaal dat aansluit op ten minste één opstaande rand een ruimte opvult tussen de opstaande rand en de celgestructureerde tussenlaag.7. Laminated panel as claimed in any of the foregoing claims, characterized in that the cured filling material that connects to at least one upright edge fills a space between the upright edge and the cell-structured intermediate layer. 8. Gelaagd paneel volgens een der voorgaande conclusies, met het kenmerk, dat het uitgeharde vulmateriaal dat aansluit op ten minste één opstaande rand ten minste een deel van de celgestructureerde tussenlaag vult.A laminated panel according to any one of the preceding claims, characterized in that the cured filling material that connects to at least one upright edge fills at least part of the cell-structured intermediate layer. 9. Gelaagd paneel volgens een der voorgaande conclusies, met het kenmerk, dat het uitgeharde vuimateriaal een gemodificeerde PU- en/of acryl-lijm is.A laminated panel according to any one of the preceding claims, characterized in that the cured filling material is a modified PU and/or acrylic adhesive. 10. Gelaagd paneel volgens een van de voorgaande conclusies, met het kenmerk, dat zich in de cellen van de celgestructureerde tussenlaag een voorgeschuimd fenolschuim bevindt.A laminated panel according to any one of the preceding claims, characterized in that a pre-foamed phenolic foam is present in the cells of the cell-structured intermediate layer. 11. Gelaagd paneel volgens een van de voorgaande conclusies, met het kenmerk, dat de cellen van de celgestructureerde tussenlaag direct zijn afgesloten door de binnenzijden van de eerste en tweede buitenste paneellagen.A laminated panel according to any one of the preceding claims, characterized in that the cells of the cell-structured intermediate layer are closed directly by the inner sides of the first and second outer panel layers. 12. Gelaagd paneel volgens een der voorgaande conclusies, met het kenmerk, dat zich tussen de binnenzijden van de buitenste paneellagen tevens ten minste één afstandsblok bevindt.12. Laminated panel as claimed in any of the foregoing claims, characterized in that at least one spacer block is also located between the inner sides of the outer panel layers. 13. Gelaagd paneel volgens een van de voorgaande conclusies, met het kenmerk, dat de celgestructureerde tussenlaag een honingraatvormig gestructureerde laag is, bij voorkeur een metalen honingraatvormig gestructureerde lag, of een met fenol geïmpregneerde papieren honingraatvormig gestructureerde laag.A laminated panel according to any one of the preceding claims, characterized in that the cell-structured intermediate layer is a honeycomb-structured layer, preferably a metal honeycomb-structured layer, or a phenol-impregnated paper honeycomb-structured layer. 14. Gelaagd paneel volgens een der voorgaande conclusies, met het kenmerk, dat het in het gelaagde paneel gebruikte lijmmateriaal een lijm is, bijvoorbeeld een polyurethaanlijm, en/of een dubbelzijdig klevende acrylschuimtape, bijvoorbeeld een VHB-tape TM,A laminated panel according to any one of the preceding claims, characterized in that the adhesive material used in the laminated panel is an adhesive, for example a polyurethane adhesive, and/or a double-sided adhesive acrylic foam tape, for example a VHB tape TM, 15. Gelaagd paneel volgens een der voorgaande conclusies, met het kenmerk, dat het ten minste ene afstandsblok samenvalt met de contour van ten minste de eerste of tweede buitenste paneellaag.A laminated panel according to any one of the preceding claims, characterized in that the at least one spacer block coincides with the contour of at least the first or second outer panel layer. 16. Gelaagd paneel volgens een der voorgaande conclusies, met het kenmerk, dat de eerste en/of tweede buitenste paneellaag een enkele metaallaag, een gecoate metaallaag, een glaslaag, een kunststoflaag, een steenlaag of een meervoudige laag is.A laminated panel according to any one of the preceding claims, characterized in that the first and/or second outer panel layer is a single metal layer, a coated metal layer, a glass layer, a plastic layer, a stone layer or a multiple layer. 17. Werkwijze voor het vervaardigen van een meerlaags paneel volgens een van de voorgaande conclusies, omvattende de bewerkingsstappen: A) het aanpassen van een eerste en een tweede buitenste paneellaag op gespecificeerde vorm en afmetingen; B) het aan ten minste één langszijde van ten minste de eerste paneellaag aanbrengen van ten minste één opstaande rand; C) het in een in hoofdzaak horizontale positie plaatsen van de eerste buitenste paneellaag; D) het aan de binnenzijde van de eerste buitenste paneellaag plaatsen van een celgestructureerde tussenlaag direct met een tussenliggend hechtmateriaal tussen de eerste buitenste paneellaag en de celgestructureerde tussenlaag; E) het in ten minste een ruimte grenzend aan ten minste één opstaande rand brengen van een uithardbaar vuimateriaal; F) het direct op celgestructureerde tussenlaag plaatsen van de binnenzijde van de tweede buitenste paneellaag met alleen een tussenliggend hechtmateriaal tussen de celgestructureerde tussenlaag en de tweede buitenste paneellaag; en G) het op een stapel van de eerste buitenste paneellaag, het hechtmateriaal, de celgestructureerde tussenlaag, het hechtmateriaal en de tweede buitenste paneellaag uitoefenen van een druk.A method for manufacturing a multi-layer panel according to any one of the preceding claims, comprising the processing steps of: A) adapting a first and a second outer panel layer to specified shape and dimensions; B) arranging at least one upright edge on at least one longitudinal side of at least the first panel layer; C) placing the first outer panel layer in a substantially horizontal position; D) placing on the inside of the first outer panel layer a cell-structured interlayer directly with an intermediate bonding material between the first outer panel layer and the cell-structured interlayer; E) placing a hardenable filling material in at least a space adjacent to at least one upright edge; F) placing the inside of the second outer panel layer directly on top of the cell-structured interlayer with only an intermediate bonding material between the cell-structured interlayer and the second outer panel layer; and G) applying a pressure to a stack of the first outer panel layer, the adhesive material, the cell-structured interlayer, the adhesive material and the second outer panel layer. 18. Werkwijze voor het vervaardigen van een meerlaags paneel volgens conclusie 17, met het kenmerk, dat ten minste één bevestigingselement, zoals een pot-inzet (“potting insert”) en/of helicoil, zodanig in ten minste één van de paneellagen wordt bevestigd dat het bevestigingselement ten minste gedeeltelijk is ingebed in het uitgeharde vulmateriaal.18. Method for manufacturing a multi-layer panel according to claim 17, characterized in that at least one fixing element, such as a pot insert and/or helicoil, is fixed in such a way in at least one of the panel layers that the fastener is at least partially embedded in the cured filling material. 19. Werkwijze voor het vervaardigen van een meerlaags paneel volgens conclusie 17 of 18, met het kenmerk, dat voorafgaand aan stap F) aan de binnenzijde van de eerste buitenste paneellaag ten minste één afstandsblok wordt geplaatst met een tussenliggend hechtmateriaal, bijvoorbeeld een dubbelzijdig plakband, tussen tenminste het afstandsblok en de eerste buitenste paneellaag.19. Method for manufacturing a multi-layer panel according to claim 17 or 18, characterized in that prior to step F) at least one spacer block is placed on the inside of the first outer panel layer with an intermediate bonding material, for instance a double-sided adhesive tape, between at least the spacer block and the first outer panel layer. 20. Werkwijze voor het vervaardigen van een meerlaags paneel volgens een van de conclusies 17 - 19, met het kenmerk, dat het lijmmateriaal aan de binnenzijde van de eerste en de tweede buitenste paneellaag tegen de celgestructureerde tussenlaag wordt geplaatst voordat de eerste of tweede buitenste paneellaag wordt aangebracht.A method for manufacturing a multi-layer panel according to any one of claims 17 - 19, characterized in that the adhesive material on the inside of the first and second outer panel layers is placed against the cell-structured intermediate layer before the first or second outer panel layer. is applied. 21. Werkwijze voor het vervaardigen van een meerlagig paneel volgens een van de conclusies 17 - 20, met het kenmerk, dat druk wordt aangebracht op de stapel van de eerste buitenste paneellaag, het kleefmateriaal, de celgestructureerde tussenlaag, het kleefmateriaal en de tweede buitenste paneellaag door de stapel door een pers te bewegen.A method of manufacturing a multilayer panel according to any one of claims 17 to 20, characterized in that pressure is applied to the stack of the first outer panel layer, the adhesive material, the cell-structured intermediate layer, the adhesive material and the second outer panel layer by moving the stack through a press.
NL2028452A 2021-06-14 2021-06-14 Reinforced multi-layered panel and method for producing such a reinforced multi-layered panel NL2028452B1 (en)

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US20020172794A1 (en) * 2001-05-18 2002-11-21 Jamco Corporation Vacuum heat-insulating panel and method of manufacturing the same
US20110183104A1 (en) * 2008-09-03 2011-07-28 Juergens Manuela Richter Sandwich panel with integrated reinforcing structure and method for the production thereof
NL2021949B1 (en) 2018-11-07 2020-05-15 Tabb Interior Systems B V Method for producing a layered panel and layered panel
WO2020242307A1 (en) * 2019-05-27 2020-12-03 Tabb Interior Systems B.V. Thermo-insulated multi-layered panel and method for producing such a thermo-insulated multi-layered panel
WO2020252124A1 (en) * 2019-06-11 2020-12-17 Continental Structural Plastics, Inc. Composite material vehicle component construct

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020172794A1 (en) * 2001-05-18 2002-11-21 Jamco Corporation Vacuum heat-insulating panel and method of manufacturing the same
US20110183104A1 (en) * 2008-09-03 2011-07-28 Juergens Manuela Richter Sandwich panel with integrated reinforcing structure and method for the production thereof
NL2021949B1 (en) 2018-11-07 2020-05-15 Tabb Interior Systems B V Method for producing a layered panel and layered panel
WO2020242307A1 (en) * 2019-05-27 2020-12-03 Tabb Interior Systems B.V. Thermo-insulated multi-layered panel and method for producing such a thermo-insulated multi-layered panel
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