Panel structure

Abstract

A panel structure and a method of forming the panel structure are disclosed. The panel structure typically includes at least one panel or support associated with an activation material. The panel structure has been found particularly advantageous for use as an interior panel of an airplane although multiple other uses are contemplated as well.

1 . An interior panel structure for a transportation vehicle, the structure comprising: 
 at least one panel;    a strip of activatable material adjacent the at least one panel and extending along a peripheral region of the panel structure, the activatable material having one or more of the following characteristics and ingredients: 
 i) a level of ductility that allows the material to be stretched such that a second cross-sectional area of the material can become less than half of a first original cross-sectional area of the material at the same location prior to rupture of the material;  
 ii) a blowing agent and a curing agent.  
   
   
   
       2 . A structure as in  claim 1  wherein the at least one panel includes a first panel and a second panel and the strip of activatable material is located at least partially between the first panel and second panel.  
   
   
       3 . A structure as in  claim 1  wherein the transportation vehicle is an airplane and the panel structure is configured for location within the fuselage of the airplane after activation of the activatable material and smoothing of the edges of the panel structure.  
   
   
       4 . A structure as in  claim 1  wherein the activatable material includes an epoxy resin, a thixotropic filler.  
   
   
       5 . A structure as in  claim 1  wherein the activatable material is activatable to soften, expand and cure upon exposure to heat.  
   
   
       6 . A structure as in  claim 1  wherein the material is a thermosettable and includes a Carboxyl/Acrylonitrile/Butadiene Rubber.  
   
   
       7 . A structure as in  claim 1  wherein, upon activation, the material is configured to adhere to the at least one panel.  
   
   
       8 . A structure as in  claim 1  wherein the material is at least partially cured prior to activation of the material.  
   
   
       9 . An interior panel structure for an airplane, the structure comprising: 
 a first panel and a second panel, the first panel generally opposing the second panel;    a support between the first panel and the second panel;    a strip of activatable material located within a gap between the first and second panels adjacent an edge of the support, the activatable material having one or more of the following characteristics and ingredients: 
 i) a level of ductility that allows the material to be stretched such that a second cross-sectional area of the material can become less than half of a first original cross-sectional area of the material at the same location prior to rupture of the material;  
 ii) epoxy resin, a blowing agent and a curing agent;  
   wherein the activatable material activates, upon exposure to heat, to foam and adhere to the first panel, the second panel and the support.    
   
   
       10 . A structure as in  claim 9  wherein the panel structure is configured for location within the fuselage of the airplane after activation of the activatable material and smoothing of the edges of the panel structure.  
   
   
       11 . A structure as in  claim 9  wherein the activatable material includes a fire retardant.  
   
   
       12 . A structure as in  claim 9  wherein the material is a thermosettable and includes a butadiene nitrile rubber.  
   
   
       13 . A structure as in  claim 9  wherein the activatable material is at least partially cured prior to activation of the material.  
   
   
       14 . A structure as in  claim 9  wherein the activatable material is only slightly tacky or substantially non-tacky to the touch prior to activation.  
   
   
       15 . A structure as in  claim 9  wherein the epoxy resin includes a liquid epoxy resin and a solid epoxy resin.  
   
   
       16 . An interior panel structure for an airplane, the structure comprising: 
 a first panel and a second panel, the first panel generally opposing the second panel;    a honeycomb support between the first panel and the second panel;    a strip of activatable material located within a gap between the first and second panels adjacent an edge of the support, the activatable material having one or more of the following characteristics and ingredients: 
 i) a level of ductility that allows the material to be stretched such that a second cross-sectional area of the material can become less than half of a first original cross-sectional area of the material at the same location prior to rupture of the material;  
 ii) epoxy resin, nitrile rubber, ammonium polyphosphate, a blowing agent and a curing agent; and  
 iii) the activatable material is substantially non-tacky prior to activation;  
   wherein the activatable material activates, upon exposure to heat, to foam and adhere to the first panel, the second panel and the support.    
   
   
       17 . A structure as in  claim 16  wherein the panel structure is configured for location within the fuselage of the airplane after activation of the activatable material and smoothing of the edges of the panel structure.  
   
   
       18 . A structure as in  claim 17  wherein the material is a thermosettable and includes a butadiene nitrile rubber.  
   
   
       19 . A structure as in  claim 18  wherein the activatable material is at least partially cured prior to activation of the material.  
   
   
       20 . A structure as in  claim 19  wherein the epoxy resin includes a liquid epoxy resin and a solid epoxy resin.