Hybrid spray booth for powder coating systems

A method for making a cored composite structure, comprising:

• positioning a first polyester film in a tool as a tooling surface;
• positioning a first composite layer over said film;
• positioning a closed cell foam core over said first composite layer;
• positioning a second composite layer over said core;
• positioning a second polyester film over said second composite layer;
• and
• curing said structure.

An electrostatic powder spray booth comprising:

• a first cored composite wall;
• a second cored composite wall;
• and a nonconductive member that is joined to each of said first and second walls to form a mechanical joint therebetween;
• wherein said first cored composite wall includes a first end that is coped with a first end of said second cored composite wall structure and bonded thereto to form a mechanical joint.

An electrostatic powder spray booth comprising:

• a first cored composite wall;
• a second cored composite wall;
• and a nonconductive member that is joined to each of said first and second walls to form a mechanical joint therebetween;
• wherein said first and second wall structures are generally flat panels and are joined to each other along a respective edge to form an included angle of about 90 degrees;
• said nonconductive member covering an otherwise exposed edge of core material of at least one of said wall structures.

In an electrostatic spray booth of the type having a vertical wall and a gun slot formed in the vertical wall, the improvement comprising:

• a non-conductive member having a hollow body and a flange extending from said body;
• said body being mountable on the vertical wall near the gun slot;
• and at least one blow-off nozzle mounted on said flange to blow powder from a spray gun that extends into said gun slot;
• said hollow body having an air manifold therein connectable to a source of pressurized air;
• said nozzle being connectable to said air manifold to receive pressurized air there from.

A method for making a cored composite wall structure used in an electrostatic spray booth, comprising:

• forming a first cured layer of fiber reinforced resin;
• forming a second cured layer of fiber reinforced resin;
• disposing a foam core between said first and second cured layers;
• applying a bonding material between said core and each of said first and second cured layers;
• and
• curing said bonding material to from a composite structure.

A composite wall structure, comprising:

• a first composite layer;
• a second composite layer;
• a structural core of cured fiber reinforced resin;
• and
• a bonding material for bonding said first and second layers to said core.