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US 2020/0005755 A1Published application
Composite Sandwich Panel Comprising Honeycomb Core and Layer of Damping or Attenuation Material
AssigneeZephyros, Inc.
InventorsChristophe Chaut, Jerome Matrat, Laura Sivec
Life of this patent
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Abstract
The invention relates generally to a panel structure that incorporates one or more panels and a material for providing reinforcement, baffling, sealing, sound absorption, damping or attenuation, thermal insulation, combinations thereof or the like.
Claims31
1:
- A reinforcement element comprising cell walls forming an array of hollow columnar cells,
- wherein each columnar cell comprises a cavity which is surrounded by cell walls, and
- wherein the reinforcement element comprises at least one coated columnar cell comprising a cavity which is surrounded by cell walls, wherein an inner surface of a cell wall towards the cavity of the at least one coated columnar cell is at least partially covered with a layer of a damping or attenuation material;
- wherein the damping or attenuation material does not completely fill the cavity of the coated columnar cell, but forms a layer on the inner surface of the cell wall towards the cavity of the coated columnar cell;
- and
- wherein the damping or attenuation material comprises an activated blowing agent.
3 more elements
2-6. (canceled)
7:
- The reinforcement element according to claim 1, wherein at least about 5% up to about 100%, preferably at least about 50% of the total number of columnar cells (3) contained in the reinforcement element (1) are coated columnar cells (3′).
(canceled)
9:
- The reinforcement element according to claim 1, wherein the cell walls are made of a resin impregnated fibrous material, wherein the fibrous material comprises paper, aramid fibers, carbon fibers, glass fibers, or mixtures thereof.
10-16. (canceled)
17:
- The reinforcement element according to claim 9, wherein at least about 5%, preferably at least about 30%, more preferably about 30% to about 90% o of the inner surface of the cell wall towards the cavity of the at least one coated columnar cell is covered with a layer of the damping or attenuation material.
18:
- The reinforcement element according to claim 9, wherein the at least one coated columnar cell has a total height;
- wherein the inner surface of the cell wall towards the cavity of the at least one coated columnar cell is partially covered with the layer of the damping or attenuation material to a covered height;
- and
- wherein the relative ratio of the covered height to the total height is within the range of from about 0.05 to about 1.0, preferably from about 0.3 to about 0.9.
1 more element
19-27. (canceled)
28:
- The reinforcement element according to claim 1, wherein the damping or attenuation material comprises an epoxy resin.
29:
- The reinforcement element according to claim 28, wherein the damping or attenuation material comprises a cross-linker for the epoxy resin, preferably dicyandiamide.
30:
- The reinforcement element according to claim 28, wherein the damping or attenuation material comprises a viscosity modifier, preferably a hydrocarbon resin.
31-34. (canceled)
35:
- The reinforcement element according to claim 9, wherein the damping or attenuation material comprises an activated blowing agent, preferably an activated chemical blowing agent, preferably prior to activation having an activation temperature within the range of from about 100° C. to about 200° C., preferably from about 140° C. to about 160° C.
36:
- The reinforcement element according to claim 1, wherein the damping or attenuation material is not substantially foamed.
37-40. (canceled)
41:
- The reinforcement element according to claim 9, wherein the damping or attenuation material comprises or essentially consists of a thermoset material.
42-43. (canceled)
44:
- The reinforcement element according to claim 1, wherein the damping or attenuation material is an adhesive, preferably a cured adhesive.
45:
- A panel structure for providing sound absorption, damping or attenuation comprising the reinforcement element according to claim 1.
46:
- The panel structure according to claim 45, which comprises a first face sheet and optionally a second face sheet, wherein the reinforcement element extends between the first face sheet and the optionally present second face sheet.
47-56. (canceled)
57:
- A process for the production of a reinforcement element according to claim 1, comprising the steps of:
- (i) providing a reinforcement element comprising cell walls forming an array of hollow columnar cells, wherein each columnar cell comprises a cavity which is surrounded by cell walls;
- and
- (ii) at least partially covering an inner surface of a cell wall towards at least one cavity with a layer of a damping or attenuation material thereby providing at least one coated columnar cell.
1 more element
(canceled)
59:
- The process according to claim 57, wherein step (ii) comprises the substeps of:
- (ii-A) providing the damping or attenuation material in the form of a sheet;
- (ii-B) placing the array of hollow columnar cells in essentially vertical arrangement with respect to the longitudinal direction of extension of the columnar cells;
- (ii-C) placing the sheet of the damping or attenuation material on top of the hollow columnar cells;
- (ii-D) heating the damping or attenuation material to a temperature above its melting temperature thereby allowing the damping or attenuation material to flow inside the hollow columnar cells, preferably driven by gravitational force, thereby at least partially covering an inner surface of a cell wall towards a cavity of the at least one coated columnar cell with a layer of a damping or attenuation material;
- and
- (ii-E) cooling the reinforcement element to a temperature below the melting temperature of the damping or attenuation material.
4 more elements
60:
- The process according to claim 59, wherein the damping or attenuation material comprises a heat-activatable blowing agent and wherein in substep (ii-D) the damping or attenuation material is heated to a temperature above the activation temperature of the blowing agent thereby activating the blowing agent.
61:
- The process according to claim 60, wherein the activation of the blowing agent promotes the flow of the damping or attenuation material inside the hollow columnar cells, preferably driven by gravitational force.
62:
- The process according to claim 59, wherein in substep (ii-C) the sheet of the damping or attenuation material is placed on top of only some of the hollow columnar cells that are contained in the array of hollow columnar cells such that substep (ii-D) yields an array comprising uncoated columnar cells as well as coated columnar cells.
63-64. (canceled)
65:
- A process for the production of a panel structure according to claim 45, comprising the process for the production of a reinforcement element according to claim 57 and the step of (iii) applying a first face sheet and optionally a second face sheet to the reinforcement element, such that the reinforcement element extends between the first face sheet and the optionally present second face sheet.
66-68. (canceled)
Dependencies are inferred from the claim text.