sandwich panel joint and method of joining sandwich panels

Abstract

Structural connections between foam cored composite panels are formed using structural bonding tape. The structural bonding tape includes a structural adhesive layer and a reinforcement fabric of fibers at least partially embedded within the layer of adhesive. The structural adhesive is cured upon exposure to ultraviolet radiation.

1 . A joint connecting a first sandwich panel and a second sandwich panel, the joint comprising:
 a first sandwich panel having a first outer layer and a second outer layer spaced from the first outer layer by a panel core, and an edge comprised of an edge portion of the panel core, an edge portion of the first outer layer and an edge portion of the second outer layer;   a second sandwich panel having a first outer layer and a second outer layer spaced from the first outer layer by a panel core, and an edge comprised of an edge portion of the panel core, an edge portion of the first outer layer and an edge portion of the second outer layer, wherein the edges of the sandwich panels are in contact with one another at an interface between the panels; and   a structural bond formed at the interface on the first outer surfaces of the panels, the structural bond comprising a layer of structural adhesive material and at least one reinforcement fabric of fibers at least partially embedded within the layer of adhesive material, wherein the structural adhesive layer is cured upon exposure to ultraviolet radiation.   
   
   
       2 . The joint of  claim 1  wherein the layer of adhesive material comprises at least one UV curable resin chosen from (meth)acrylates, epoxy, polyurethanes, vinyl esters, polyester, phenolic, silicone resins, and mixtures of two or more thereof. 
   
   
       3 . The joint of  claim 1  wherein the layer of adhesive material comprises at least one UV curable (meth)acrylate resin. 
   
   
       4 . The joint of  claim 1  wherein the reinforcement fabric of fibers is chosen from fiberglass mesh, woven fabrics, non-woven fabrics, knitted fabrics and a unidirectional array of fibers. 
   
   
       5 . The joint of  claim 1  wherein the fibers of the reinforcement fabric are chosen from polyester, polyolefin, aramid, cotton, sisal, jute, hemp, glass, carbon, ceramic, and coated fibers having a core component and a coating thereon. 
   
   
       6 . The joint of  claim 1  wherein the reinforcement fabric of fibers comprises a fiberglass mesh. 
   
   
       7 . The joint of  claim 1  further comprising a second structural bond formed at the interface on the second outer surfaces of the panels, the structural bond comprising a layer of structural adhesive material and at least one reinforcement fabric of fibers at least partially embedded within the layer of adhesive material, wherein the structural adhesive layer is cured upon exposure to ultraviolet radiation. 
   
   
       8 . A method of joining sandwich panels comprising:
 providing a first sandwich panel having a first outer layer and a second outer layer spaced from the first outer layer by a panel core, and an edge comprised of an edge portion of the panel core, an edge portion of the first outer layer and an edge portion of the second outer layer;   providing a second sandwich panel having a first outer layer and a second outer layer spaced from the first outer layer by a panel core, and an edge comprised of an edge portion of the panel core, an edge portion of the first outer layer and an edge portion of the second outer layer;   contacting the edges of the sandwich panels with one another at an interface between the panels;   applying a bonding tape to the interface on the first outer surfaces of the panels, the bonding tape having an inner surface and an outer surface and comprising a layer of ultraviolet curable structural adhesive material and at least one reinforcement fabric of fibers at least partially embedded within the layer of adhesive material; and   exposing the adhesive material to a source of ultraviolet radiation to form a structural bond between the first panel and the second panel at the interface.   
   
   
       9 . The method of  claim 8  wherein the layer of adhesive material comprises at least one UV curable resin chosen from (meth)acrylates, epoxy, polyurethanes, vinyl esters, polyester, phenolic, silicone resins, and mixtures of two or more thereof. 
   
   
       10 . The method of  claim 8  wherein the layer of adhesive material comprises at least on UV curable (meth)acrylate resin. 
   
   
       11 . The method of  claim 8  wherein the reinforcement fabric of fibers is chosen from fiberglass mesh, woven fabrics, non-woven fabrics, knitted fabrics and a unidirectional array of fibers. 
   
   
       12 . The method of  claim 8  wherein the fibers of the reinforcement fabric are chosen from polyester, polyolefin, aramid, cotton, sisal, jute, hemp, glass, carbon, ceramic, and coated fibers having a core component and a coating thereon. 
   
   
       13 . The method of  claim 8  wherein the reinforcement fabric of fibers comprises a fiberglass mesh. 
   
   
       14 . The method of  claim 8  wherein the source of ultraviolet radiation is sunlight. 
   
   
       15 . The method of  claim 8  wherein the bonding tape further comprises an opaque overlay film on the outer surface. 
   
   
       16 . The method of  claim 15  wherein the opaque overlay film is removed prior to exposure to ultraviolet radiation. 
   
   
       17 . An architectural edifice comprising the joint of  claim 1 . 
   
   
       18 . An architectural edifice made according to the method of  claim 8 .