Method of Producing a Structural Panel and Panel Produced by the Method

The invention relates to a method of producing a structural panel such as a visually attractive lightweight structural panel for use in partition walls or in the aircraft passenger cabins. Such panels generally have a lightweight composite panel core and a colored image or pattern applied to one of its surfaces.

Structural panels of this kind are generally used as cabin partition walls or side walls of storage cabinets in passenger aircraft. Such panel walls generally comprise a lightweight composite panel core with a visually attractive colorful pattern or image on the surface. The material of which these panels and especially the cover layers of these panels are made, is fiber reinforced composite material. In prior art methods, exposed surfaces which are to receive a colorful patterned coating such as a paint coating must first be prepared by the following steps: grinding the surface; filling the surface pores with a pore filling material; smoothing the filler material; grinding and polishing the filled surface; and base coating.

The various process steps for smoothing the surface of the lightweight composite panels are necessary because the respective cover layers of the composite panels comprise an uneven surface having a waviness caused by the production method of the composite panel. The waviness is caused, because the honeycomb core of the composite panel only supports the cover layers of the composite panel in the areas of the honeycomb walls and not in the hollow core spaces or voids, so that depressions or dimples are formed in the cover layer in the areas of the honeycomb voids or hollow spaces. The machining steps for planing or smoothing the surface of such panels are very time consuming and greatly increase the production costs. Making the surface of such honeycomb panels smooth also requires thicker cover layers than would be needed if the depressions or dimples may remain visible. It is a considerable disadvantage of the prior art method that the colorful attractive pattern or image layer can only be applied after the surface of the panel has been prepared in the above mentioned smoothing or planing steps if the dimples are to be avoided.

In view of the foregoing it is the aim of the invention to achieve the following objects singly or in combination:

to provide a simplified method of producing a structural panel having a smooth surface without dimples and preferably a visually attractive colored pattern or image on the surface even if the panel has a honeycomb core;

to eliminate the appearance of surface uneveness, dimples, or waviness in a panel without needing surface machining or planing steps;

to provide a method for decorating a panel surface which may be carried out relatively quickly, simply, and inexpensively so that the finished panels are inexpensive;

to allow a visually attractive surface treatment to be applied to such a panel practically simultaneously with the production of the panel, whereby the production process may be greatly accelerated; and

to provide a lightweight and visually attractive structural panel made by the method of the invention.

These objects have been achieved in a method of producing a structural panel according to the invention and in a structural panel produced according to this method. The method according to the invention includes the following steps: cleaning the surface of a core or panel substrate of a structural panel having a honeycomb core with its cover layers; applying an adhesive layer to the cleaned surface of the panel substrate; adhering or pressing an aluminum sheet onto the adhesive layer applied on the structural panel substrate; curing the adhesive layer to form an adhesive bond between the aluminum sheet and the structural panel substrate; cleaning the outer surface of the aluminum sheet; applying and curing a base coat onto the clean surface of the aluminum sheet; and applying layers of color onto the base coat to produce a visually attractive pattern or colored image.

Alternatively, the visual image or colored pattern may first be applied to the aluminum sheet and then the aluminum sheet may be glued to the structural panel substrate or core. In both instances the aluminum sheet covers the undesired depressions on the panel surface.

In order that the invention may be clearly understood, it will now be described, by way of example, with reference to the accompanying drawings, wherein the single figure is an exploded perspective view of a structural decorative panel produced according to the method of the invention.

The figure shows a portion of a structural panel in an exploded perspective view. The panel may, for example, be used to form interior partition walls and storage compartment walls in passenger cabins of aircraft or other craft. The structural panel has a lightweight composite substrate 1 including a honeycomb core 2 and top and bottom cover sheets 3 and 4. In this example embodiment it will be assumed that only the top cover sheet 3 is to be provided with a colored pattern or a visually attractive image carrying an ornamental colored layer 8 on a base coat 7 on an aluminum sheet 6 bonded to the surface of the cover sheet 3 by an adhesive 5. In order to achieve this, the method of the invention is carried out by the following steps:

(a) cleaning the surface of the cover sheet 3 of the lightweight composite panel substrate 1;

(b) applying an adhesive layer 5 to the cleaned surface;

(c) adhering or pressing an aluminum sheet 6 onto the adhesive layer 5;

(d) curing the adhesive layer 5 to form an adhesive bond between the aluminum sheet 6 and the lightweight composite panel substrate 1;

(e) cleaning the top surface of the aluminum sheet 6;

(f) applying and curing a base coat layer 7; and

(g) applying at least one colored layer 8 to form a visual image or attractive colored pattern. The layer 8 as such may be formed in any known manner, for example, by means of spraying, brush painting, roller coating, etc. In a variation of the above described method according to the invention, the aluminum sheet 6 is clamped into a carrying jig and the method steps (e) to (g) are carried out, whereby the desired visual image is formed on the aluminum sheet 6 before it is bonded to the panel substrate 1. In order to attach or clamp the aluminum sheet 6 to the carrying apparatus, small tabs or protrusions are provided on the aluminum sheet. In this embodiment of the invention, it is possible to produce or apply the desired visual image to the surface of the aluminum sheet while the respective structural panel is still being produced. In this manner the visual image and the structural panel are produced practically simultaneously, whereby the production throughput may be considerably accelerated. In both instances, the aluminum sheet has a thickness of about 0.3 to about 0.4 mm, which has been found sufficient to avoid the dimples in the panel surface.

The materials used to produce the structural panel as well as the visual image may be freely selected so that, for example, materials may be chosen which have optimum low toxicity and smoke development in case of fire. The panel substrates may be covered with ornaments on both sides in the manner described above for one side. Partition walls may, for example, require an ornamentation on both sides.

The aluminum sheet 6 is preferably bonded to the surface of the cover sheet 3 by an adhesive selected from the following group: Epoxide, Polyurethane, Polyester Polyamide having a curing temperature within the range of about 50.degree. C. to about 80.degree. C. Hereby the hardening takes place within a few hours compared to about 14 hours at 20.degree. C.

Advantages of the invention are seen in that the aluminum sheet effectively covers the above mentioned depressions or dimples so that surface smoothing or planing operations of the substrate are avoided, thereby substantially reducing costs. Further, the lightweight composite substrate may be formed while the aluminum sheet is prepared and decorated simultaneously so that the finished product results from bonding the decorated aluminum sheet to the prepared substrate.

Although the invention has been described with reference to specific example embodiments it will be appreciated that it is intended to cover all modifications and equivalents within the scope of the appended claims.