In mold painting of lightweight core structure assembly with vehicle exterior surface finish

Abstract

A composite sandwich panel structure is provided with a lightweight core sandwiched between a high gloss surface sheet and an optically uniform painted or otherwise finished structural skin that are adhered to the lightweight core so as to reduce delamination of the formed part. The structural skin is surface finished during the formation of the sandwich panel structure and does not require any post manufacturing finishing steps such as a separate painting step or material application step. The sandwich composite structure, the high gloss surface sheet, and structural skin are adhered to the lightweight core with an adhesive or glue that is viscous when applied. The viscosity of the adhesive as applied allows for contact with the interior volume of the lightweight core to create more adhesion surface area yet without excessively running into the pores defined in the lightweight core before the adhesive cures or hardens.

Dependencies are inferred from the claim text.