Dual panel fabrication

Abstract

A pair of laminated panels are simultaneously manufactured in a single panel press. A thermal band is stacked between two panel sets and then the two panel sets are simultaneously heated and compressed together in a common stack with the band, with the band being separately heated.

Accordingly, what is desired to be secured by Letters Patent of the United States is the invention as defined and differentiated in the following claims in which I claim: 
     
       1. A method of making a laminated panel in a panel press having adjacent platens, comprising:
 compressing together between said adjacent platens in said panel press two sets of panel laminates on opposite sides of a thermal band; and 
 each of said panel sets comprising a honeycomb core laminated between top and bottom skins, and an adhesive ply laminated between said core and skins; 
 heating said two sets of panel laminates along opposite top and bottom sides thereof;  
 circulating heating fluid internally through said platens and separately heating said thermal band to internally heat said two panel sets and thermally bond together said panel laminates in each of said two panel sets to double production capability of said panel press; 
 measuring temperature of said internal heating; and 
 powering said thermal band in response to said measured temperature of said internal heating. 
 
     
     
       2. A method according to  claim 1  further comprising:
 assembling said two sets of panel laminates; 
 stacking together said two panel sets on opposite sides of said thermal band in a collective dual panel group having said opposite top and bottom sides; and 
 compressing together said dual panel group between said adjacent platens in said panel press. 
 
     
     
       3. A method according to  claim 2  further comprising:
 placing said dual panel group in a common slot between top and bottom platens inside said panel press; 
 compressing together said platens to compress said dual panel group; and 
 circulating heating fluid through said platens to heat correspondingly said opposite top and bottom sides of said dual panel group, and separately heating said thermal band to internally heat said dual panel group and thermally bond together said panel laminates in each of said two panel sets to correspondingly form two laminated panels. 
 
     
     
       4. A method according to  claim 3  further comprising:
 circulating cooling fluid through said platens to cool said laminated panels; and 
 removing said two panels from said platens and thermal band. 
 
     
     
       5. A method according to  claim 3  further comprising:
 measuring temperature of one of said heated platens; 
 measuring temperature of said thermal band; and 
 powering said thermal band to match said measured temperature thereof to said measured temperature of said one platen. 
 
     
     
       6. A method according to  claim 3  further comprising:
 assembling multiple groups of said two panel sets with corresponding thermal bands; 
 placing said multiple groups in corresponding slots between a plurality of stacked platens; 
 compressing together said stack of platens to simultaneously compress said multiple groups; and 
 heating said stacked platens and corresponding thermal bands to collectively heat said panel laminates in each of said two panel sets in each of said multiple groups to simultaneously form multiple laminated panels. 
 
     
     
       7. A method according to  claim 6  further comprising:
 measuring temperature of said heated platens at each of said multiple groups; 
 measuring temperature of said thermal bands in each of said multiple groups; and 
 powering each of said thermal bands to match said measured temperature thereof to said measured temperature of corresponding platens. 
 
     
     
       8. A method according to  claim 3  wherein:
 said platens are mounted in a frame inside said panel press; 
 said panel press further includes an anvil fixed to said frame and an opposite wedge movably driven by piston actuators; and 
 said platens and dual panel group are disposed between said anvil and wedge, with said wedge being driven by said actuators for compression thereof. 
 
     
     
       9. A method according to  claim 8  wherein:
 said panel press further includes a temperature controller operatively joined to one of said platens and to said thermal band; and 
 said temperature controller is configured to power said thermal band to match temperature thereof to temperature of said one platen. 
 
     
     
       10. A method according to  claim 9  wherein:
 said thermal band comprises an electrical blanket having a temperature sensor embedded therein, and operatively joined to said controller; 
 said one platen includes another temperature sensor mounted therein, and operatively joined to said controller; and 
 said platens and electrical blanket are separately heated, with said electrical blanket being heated to follow heating of said platens in response to temperatures measured from said temperature sensors. 
 
     
     
       11. A method according to claim  3  2 wherein said two panel sets are identical to each other for making correspondingly identical laminated panels. 
     
     
       12. A method according to  claim 3  wherein each of said panel sets comprises a honeycomb core laminated between top and bottom skins, and an adhesive ply laminated between said core and skins. 
     
     
       13. A method according to claim  12  2 wherein said dual panel group further comprises a protective liner disposed on both sides of said thermal band and inside each of said platens directly adjoining corresponding panel skins. 
     
     
       14. A method according to  claim 13  wherein each of said protective liners comprises layers of release paper and chip board. 
     
     
       15. A method according to  claim 13  wherein said dual panel group further comprises corresponding caul sheets disposed on opposite sides thereof in opposition with said top and bottom platens. 
     
     
       16. A method according to  claim 3  wherein:
 said top and bottom platens comprise flat plates; 
 said panel laminates are flat and rectangular; and 
 said thermal band is flexible and rectangular, and heated uniformly to uniformly heat said two panels sets to produce two flat rectangular panels. 
 
     
     
       17. A method of making a pair of laminated panels comprising: 
 simultaneously heating and compressing together in a single slot between adjacent platens in a panel press two sets of panel laminates in a common stack having a separately heated thermal band in the middle thereof and heating fluid circulating internally through said platens wherein each of said panel sets comprises a honeycomb core laminated by an adhesive ply between top and bottom skins, and said thermal band comprises an electrical blanket having a temperature sensor embedded therein and operatively joined to a temperature controller, and powering said thermal band in response to measured temperature of said thermal band. 
 
     
     
       18. A method according to  claim 17  further comprising simultaneously making multiple pairs of said laminated panels in corresponding slots between by introducing in the middle thereof corresponding ones of said separately heated thermal bands instead of corresponding platens in said panel press. 
     
     
       19. A method according to  claim 18  further comprising modifying said panel press to include:
 a plurality of said thermal bands for said corresponding slots common stacks therein; 
 a plurality of temperature sensors for said platens and thermal bands to measure temperature thereof; and 
 asaid temperature controller is configured to power said thermal bands for followingin response to measured temperature of said platensthereof. 
 
     
     
       20. A panel press for manufacturing multiple laminated panels, said press comprising:
 a plurality of platens mounted in a frame, and defining corresponding slots therebetween; 
 an anvil fixed to a frame, and an opposite wedge movably driven by piston actuators for compressing multiple groups of panel laminates to correspondingly form said multiple laminated panels; 
 a plurality of thermal bands corresponding with said slots multiple laminate groups, with each group comprising two sets of panel laminates on opposite sides of a corresponding thermal band, and each of said panel sets comprises a honeycomb core laminated between top and bottom skins, and an adhesive ply laminated between said core and skins; 
 a plurality of temperature sensors mounted in said platens and in said thermal bands for measuring temperature thereof; and 
 a temperature controller to power said thermal bands for following controlling measured temperature of said platens thereof. 
 
     
     
       21. A method according to claim 2 further comprising:
 assembling multiple groups of said two panel sets with corresponding thermal bands;   placing said multiple groups in a vertical stack in said panel press;   simultaneously compressing together in said panel press said stack of multiple groups; and   heating each of said dual panel groups along said top and bottom sides thereof and correspondingly powering said thermal bands to internally heat said panel laminates in each of said two panel sets in each of said multiple groups to simultaneously form multiple laminated panels.   
     
     
       22. A method according to claim 21 wherein:
 said panel press further includes a temperature controller operatively joined to said thermal bands; and   said temperature controller is configured to power said thermal bands to match said internal heating of said two panel sets with measured temperature of corresponding heating of said top and bottom sides in each of said multiple groups.   
     
     
       23. A method according to claim 22 wherein:
 each of said thermal bands comprises an electrical blanket having a temperature sensor embedded therein for measuring said temperature of internal heating, and said sensors are operatively joined to said temperature controller for powering said electrical blankets in feedback response to said measured temperature of internal heating.   
     
     
       24. A method according to claim 2 wherein:
 said panel laminates are flat and rectangular; and   said thermal band is flexible and rectangular, and heated uniformly to uniformly heat said two panels sets to produce two flat rectangular panels.   
     
     
       25. A method of making a laminated panel in a panel press having an anvil fixed to a frame and an opposite wedge movably driven by piston actuators, said method comprising:
 assembling multiple sets of panel laminates;   each of said panel sets including a honeycomb core laminated between top and bottom skins, and an adhesive ply laminated between said core and skins;   stacking together said multiple panel sets on opposite sides of corresponding thermal bands in collective dual panel groups having opposite top and bottom sides in each group, with a corresponding thermal band in the middle thereof;   compressing together in said panel press between said anvil and wedge said multiple panel groups;   heating said multiple panel groups along said top and bottom sides thereof;   heating said thermal bands to internally heat said multiple panel groups;   measuring temperature of said thermal band in each panel group; and   powering said thermal bands in response to said measured temperatures of said thermal bands for thermally bonding together said panel laminates in each panel group.