Patent Publication Number: US-2022212725-A1

Title: Multi-dimensional load structure

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. patent application Ser. No. 17/173,054, filed on Feb. 10, 2021, and which is a continuation of and claims priority to U.S. patent application Ser. No. 16/110,409, filed on Aug. 23, 2018, which issued at U.S. Pat. No. 10,926,809 on Feb. 23, 2021, both of which are hereby incorporated by reference in its entirety. 
    
    
     FIELD OF TECHNOLOGY 
     The present disclosure pertains to a multi-dimensional load structure that may be employed, for example, but not limited to, in a vehicle where a load is applied, such as a floor panel, roof panel, hood, deck lid, side wall, structural member, and the like, and a method of manufacturing thereof. 
     BACKGROUND 
     Load structures, i.e., structures configured to withstand loads, are employed in all different kinds of applications, including, but not limited to, in vehicles as floor panels, roof panels, and the like. These load structures are often made of a paper honeycomb and are typically formed as thin panels that have sections in which the contour and/or thicknesses vary. One method of forming the load structures is using corrugated wave board blocks that are shaped prior to processing. Another method of forming a load structure involves pre-molding the geometric shapes or features that add thickness, and then adding them to the main panel when it is formed. However, load structures formed from these methods may have unpredictable weak areas, which may affect the ability of the load structure to withstand loads in its normal application and use. 
     Accordingly, there exists a need for an improved multi-dimensional load structure and method of manufacturing thereof to increase efficiency and minimize costs of manufacturing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Referring now to the drawings, illustrative embodiments are shown in detail. Although the drawings represent some embodiments, the drawings are not necessarily to scale and certain features may be exaggerated, removed, or partially sectioned to better illustrate and explain the present disclosure. Further, the embodiments set forth herein are not intended to be exhaustive or otherwise limit or restrict the claims to the precise forms and configurations shown in the drawings and disclosed in the following detailed description. 
         FIGS. 1A and 1B  are perspective views illustrating an “A” side and “B” side of a multi-dimensional load structure according to one exemplary approach; 
         FIG. 1C  is a partial, cross-sectional view, taken from line  1 - 1  of  FIG. 1B , of the multi-dimensional load structure of  FIGS. 1A and 1B ; 
         FIG. 2  is a schematic flow diagram of an exemplary method for manufacturing a multi-dimensional load structure; 
         FIG. 3  is a schematic perspective view of a tiered structure of layers used to form the multi-dimensional load structure of  FIGS. 1A and 1B ; 
         FIG. 4  is a schematic cross-sectional view of a preform mold used to shape the tiered structure of  FIG. 3  into a panel; 
         FIGS. 5-7  are schematic, partial cross-sectional views, taken from line  3 - 3  of  FIG. 3 , of the tiered structure of  FIG. 3  through different steps of a forming process; 
         FIG. 8  is a perspective view of an additional multi-dimensional load structure; 
         FIG. 9  is a bottom view of the load structure of  FIG. 8 ; 
         FIG. 10  is a top view of the load structure of  FIG. 8 ; 
         FIG. 11A  is a partial, cross-sectional view, taken from line  11 A- 11 A of  FIG. 8 ; 
         FIG. 11B  is a partial schematic perspective view of the load structure of  FIG. 8 ; 
         FIG. 11C  is a partial schematic exploded view of the layers of the load structure of  FIG. 8 ; and 
         FIG. 12  is a schematic flow diagram of a method for manufacturing the load structure of  FIG. 8 . 
     
    
    
     DETAILED DESCRIPTION 
     An exemplary multi-dimensional load structure may include a base panel having a tiered structure with an upper layer, a lower layer, and at least one interior layer therebetween. The load structure may also have a glass layer applied to at least surfaces of each of the upper layer, the lower layer, and the at least one interior layer not in contact with an adjacent layer. The load structure may further have a coating applied to the exterior of the glass layer. The at least one interior layer may be configured to withstand a greater compressive force than the upper layer and the lower layer and/or the upper layer and the lower layer may be lighter than the at least one interior layer. The load structure may be used in vehicle, aerospace, ship, cargo, building, furniture, and other applications in which a structure is required to handle a load. 
     An exemplary method for manufacturing a multi-dimensional load structure may include first assembling a lower layer, at least one interior layer, and an upper layer to form a tiered structure. The method may then include forming the tiered structure into a panel, and then applying a glass layer to surfaces of each of the upper layer, the lower layer, and the at least one interior layer not in contact with an adjacent layer. The method may then include applying a coating to the glass layer, and finally, trimming the panel into a final shape of the multi-dimensional load structure. 
     Referring now to the figures,  FIGS. 1A through 1C  illustrate a multi-dimensional load structure  10  according to one exemplary approach. As can be seen in the figures, the load structure  10  may have varying contours and thicknesses. The sections  16  of the load structure  10  having increased thicknesses may be on a “B” side  14  of the load structure  10 , as illustrated in  FIG. 1B , which generally may not be visible or as readily visible, though it should be appreciated that such sections  16  may also be on an “A” side  12  of the load structure  10 . 
     To achieve a structure with different thicknesses and/or having a curved profile  103 , the load structure  10  may include a panel  100  having a tiered structure  101  in the areas of increased thickness and curved profile  103 , as illustrated in  FIG. 1C . The tiered structure  101  generally may have a lower layer  102 , one or more interior layers  106 , and an upper layer  104  stacked collectively on a base layer  108 . Along the curved profile  103 , the panel  100  may have deformed or crushed areas  105 , where one or more of the layers  102 ,  104 , or  106  may be deformed or crushed from its original structure during forming of the panel, as described in more detail hereinafter. While  FIG. 1C  illustrates two interior layers  106 , it should be appreciated that there may be any number of interior layers  106 , including just one. The load structure  10  also may have different numbers of interior layers  106  at different locations of the load structure  10  to form the desired shape and/or thickness. The layers  102 ,  104 ,  106 , and  108  may or may not have the same thickness (t) as one or more of the other layers. Similar to the number of layers, the thicknesses of the layers may also be dependent upon the desired shape of the panel  100 . For example, where the curved profile  103  has less of a slope, the thickness of the layers may be greater, and the quantity of layers may be less than areas where there is more of a slope. This may result in a smaller deformed or crushed area  105 . The layers  102 ,  104 , and  106  generally may be constructed such that the compressive force required to deform the interior layers  106  may be greater than that required to deform the lower and upper layers  102  and  104 . Further, the lower and upper layers  102  and  104  may be lighter than the interior layers  106 , which may help to ensure the center of the load structure, in particular, the interior layers  106 , maintain structural integrity. Thus, the load structure  10  contemplates layers of varying sizes, shapes, and thicknesses. 
     The base layer  108  may have a layer of glass to stabilize the material of the layers at expansion during the forming process, which is described in more detail hereinafter, and to provide the fiber necessary for the composite which will form the skin of the “A side”  12  of the load structure  10 . The base layer  108  generally may be large enough to accommodate handling through the forming process. The glass material may be oriented, woven, braided, random or any combination thereof, which may create the characteristics that the load structure  10  may require. 
     The layers  102 ,  104 ,  106 , and  108  may be constructed of a material including paper, composite, thermoplastic, thermoset, or a combination thereof, and generally may have material properties required to form the panel  100 . As merely one exemplary approach, one or more of the layers  102 ,  104 ,  106 , and  108  may have at least one of a base weight ranging from 65 g/m2 to 212 g/m2, a density ranging from about 0.46 g/cm3 to 0.67 g/cm3, a Taber bending stiffness and (machine direction) ranging from about 1.66 gmf-cm to 61.03 gmf-cm, and a Taber bending stiffness rd (roll direction) ranging from about 0.73 gmf-cm to 23.6 gmf-cm. Each layer  102 ,  104 ,  106 , and  108  may further have a honeycomb structure. The interior layers  106  generally may have a smaller cell construction than that of the lower and upper layers  102  and  104 . As merely one example, the interior layers  106  may have a cell diameter (d) of 6 mm whereas the lower and upper layers  102  and  104  may have a cell diameter of 10 mm. The smaller cell construction of the interior layers  106  may allow for the greater compressive force required to deform the interior layers  106 , as described above. The base layer  108  generally may be in contact with a forming tool along its entire surface. As such, the base layer  108  may be constructed with a 10 mm cell diameter honeycomb in one example. 
     The load structure  10  may also include paper layers  110  between each layer of the tiered structure  101 . The paper generally may have a construction that may ensure that the compressive forces needed to form the panel are transferred through to the panel  100  from the forming tool, as described in more detail hereinafter, and force distortion of the paper to the outside of the panel  100 . For example, the paper may be 4-40 lbs/ft 2 , and may be, but is not limited to, kraft paper. The layers  102 ,  104 , and  106  may be bonded together by an adhesive  112 . The adhesive  112  may be water based or solvent based, and generally may be compatible with urethane, e.g., does not inhibit bonding of polyurethane to the paper, the inhibiting of bonding for which may result in fogging, odor, flammability, and the like. 
     The load structure  10  may also include a glass layer  114  around the panel  100 . The glass may have a construction that is random, oriented, braided, woven, or any combination thereof. The load structure  10  may further have a coating  116  applied on and encapsulating the glass layer  114 . The coating may be, but is not limited to, polyurethane, which may be rigid, and may be a foam, for example, 0.20 g/cc to 0.35 g/cc, or non-foaming. The amount of the coating  116  may be such that the weight is substantially equal to the weight of the glass layer  114  or as necessary to encapsulate deformed honeycomb structure. 
     Referring now to  FIG. 2 , an exemplary method  200  for manufacturing a multi-dimensional load structure is illustrated. While method  200  is described hereinafter with respect to load structure  10 , it should be appreciated that method  200  may be used to form any variations or embodiments of a load structure to which the steps are applicable. Method  200  generally may begin at step  202  in which the different layers, including, but not limited to, the lower layer  102 , interior layers  106 , and upper layers  104 , may be assembled, for example, stacked, into a tiered structure  110  on a base  108  with a stepped configuration, as illustrated in  FIGS. 3 and 5 . It should be appreciated that the number of lower layers, upper layers, and interior layers may be the same or may be different, as illustrated, depending upon the final shape and profile of the load structure. As explained above, the layers  102 ,  104 , and  106  may be a paper honeycomb structure, where the interior layers  106  generally have a smaller cell construction than that of the lower and upper layers  102  and  104  such that the compressive force required to deform the interior layers  106  may be greater than that required to deform the lower and upper layers  102  and  104 . 
     Each layer may also have a paper layer  110  attached to one or more surfaces of the respective layer such that there may be a paper layer between each layer when assembled in the tiered structure  101 . The paper layer  110  may be sized and located, i.e. to cover the respective surface to which the paper is attached, to be substantially equal to the area of contact between adjacent layers, where exposed surfaces of the layers do not have the paper layer. The layers with the paper layer  110  may be bonded to one another via an adhesive, which may be compatible with urethane, and may be water based or solvent based. 
     After step  202 , method  200  may proceed to step  204  in which the tiered structure  101  may be formed into a panel  100 , as seen in  FIGS. 5 and 6 . This may be done by preforming via a preform mold that defines the desired contour, i.e., has substantially the same shape as the final load structure. During such forming, one or more of the layers  102 ,  104 , and  106  may be crushed, forming deformed or crushed areas  105 , such that the tiered structure  101  may have the curved profile  103 . A lower tool  300  according to one exemplary approach is illustrated in FIG.  4 . When the preform mold is in an open position, the lower tool  300  may have a clearance  302  from a surface of one of the layers, as seen in  FIG. 7 . As merely one example, the clearance may be between 2 and 3 mm. 
     After step  204 , method  200  may proceed to step  206  in which a glass layer  114  may be applied to the panel  100 . Step  206  may include placing the glass material on the inside of the lower tool  300 . The amount of glass material may be sized so as to cover the entire surface of the panel  100 . As explained above, the glass material may be random, oriented, braided, woven, or any combination thereof. Any reinforcements and/or inserts needed may also be placed in the inside of the lower tool  300  at this time. Then, an adhesive may be applied, for example, by spraying, on the glass material in the lower tool  300  and/or on the panel. The adhesive generally may be urethane compatible. The preform mold may then be closed to allow the adhesive to cure. 
     After step  206 , method  200  may proceed to step  208  in which a coating  116  may be applied to the glass layer  114 . Additional material may also be added at this time to fill the geometry, where needed. As explained above, the coating  116  may be, but is not limited to polyurethane, which may be rigid and foaming or non-foaming, and the amount of coating may be such that the coating encapsulates the glass layer and has a weight that is substantially equal to the weight of the glass layer. To apply the coating  116 , the panel  100  may be removed from the preform mold and placed on a load table designed to hold the panel  100  in a positive repetition. The panel  100  may then be picked off of a load station, which may be done via an end-of-arm-tool, which in turn may be attached to a robot that may transfer the panel  100  to a spray booth where the coating material, e.g., polyurethane, may be applied via spraying. The spraying may be accomplished using a fix mounted spray head or a moving spray head. The end-of-arm-tool may then transport the panel with the coating applied thereto, and transfer it back to a heated mold, which is closed and pressed until the coating has cross-linked. After the coating  116  has cured, the panel  100  may be removed from the press. 
     Method  200  may end at step  210  where the panel  100  may be trimmed. This may be performed via a matched steel tool, a rule die, in mold pinch, in mold by-pass, a waterjet cutting system, or the like. 
     The resulting panel  100  may result in a load structure  10  having varying compression, load, and performance characteristics based on a desired engineering performance behavior. Collectively, the layers  102 ,  104  and  106  may provide and be formed in to first, second, and/or third layers of a 3-D load structure  10  to create a composite sandwich that can have varying thicknesses, shapes, and/or densities, that may be tailored to unique product applications so as to provide enhanced performance characteristics. It will be appreciated that the number of layers can be 1−n. It will be further appreciated that the number of compound shapes can be 1−n, as is shown in exemplary  FIG. 1B  where at least two compound shapes are illustrated. 
     In general, the tiered structure of the panel is advantageous in that deformation of the layers, e.g., of the paper material of the honeycomb structure, during forming of the panel may occur on an outer periphery of the formed (molded) panel. The coating (polyurethane) may then encapsulate the deformed paper (in addition to the glass layer). This reduces the impact of the deformed paper on the structure of the final load structure, e.g., unpredictable weak areas. 
     Referring now to  FIGS. 8-10 , an additional multi-dimensional load structure  10  is shown. The load structure  10  may be a header bow for a vehicle  40  with a removable roof  50  (e.g., a convertible, a truck, or a SUV, among others). In some example configurations, the load structure  10  may be disposed within and/or may be connected to the removable roof  50  of the vehicle  40  (see, e.g.,  FIG. 10 , top view). The load structure  10  may include various shapes, sizes, and/or configurations. 
     The load structure  10  includes a first side  18  (e.g., a lower side) and a second side  20  (e.g., a top side) spaced apart from the first side  18 . In some configurations, when the load structure is installed onto, or in connection with, the vehicle  40 , the first side  18  may face an interior of the vehicle  40 . In some examples, the load structure  10  includes a base portion  30  and a first curved end portion  32  and a second curved end portion  34 . The first and second end portions  32 ,  34  may be disposed at terminal ends of the base portion  30 . The first and second end portions  32 ,  34  may be arranged to at least partially wrap around and/or engage portions of a frame of the vehicle  40 . It will be appreciated that while the load structure  10  is shown being used with the vehicle  40 , that components other than a header bow are contemplated as this disclosure contemplates the load structure  10  being used with other components of a vehicle or other system. Further, the load structure  10  may be an automotive, heavy duty equipment, or other device, which can be permanently part of, affixed to, or removable from a vehicle, or the like. 
     In some example configurations, the load structure  10  may include a handle  22  and one or more fasteners  24 . In some instances, the handle  22  may be arranged to face a rear end of the vehicle  40 . The handle  22  may be configured such that an operator (e.g., a driver, a passenger, a mechanic, etc.) of the vehicle  40  may manipulate the handle  22  to help facilitate the removal of the roof  50  of the vehicle  40 . 
     A fastener  24  may be configured to attach to external components (such as a feature on a vehicle) and may include one among an insert, a treaded insert, a nut, a support, a bolt, a rod, a pin, or a screw, among others. The external components may include additional components and/or portions of the removable roof  50  and/or the vehicle  40 , among other things. In some instances, the load structure  10  may include a plurality of fasteners  24 . 
     In some configurations, one or more fasteners  24  may be configured to help, at least in part, secure the load structure  10  to the removable roof  50 . In some examples, one or more latches (not depicted) may be coupled to the load structure  10  via some of the fasteners  24 . The latches may be configured to selectively lock the removable roof  50  to the vehicle  40 . 
     As can be seen in the figures, the load structure  10  may have varying contours and thicknesses. For instance, the load structure  10  may include one or more sections  16  that have increased thicknesses, a mounting pad, a boss, etc. To achieve a structure with different thicknesses and/or having a curved profile  103 , the load structure  10  may include a panel  100  having a tiered structure  101  in the areas of increased thickness and/or curved profile  103 , as illustrated in  FIG. 11A . 
     Referring now to  FIG. 11A , the tiered structure  101  generally may have a lower honeycomb layer  102 , one or more interior honeycomb layers  106 , and an upper honeycomb layer  104  stacked collectively on a base honeycomb layer  108 . In some example configurations, the tiered structure  101  includes a plurality of intermediate layers  118  disposed between one or more pairs of adjacent honeycomb layers. 
     For example, and without limitation, the intermediate layers  118  may be disposed between the base honeycomb layer  108  and the lower honeycomb layer  102 , the lower honeycomb layer  102  and an interior honeycomb layer  106 , adjacent interior honeycomb layers  106 , and/or an interior honeycomb layer  106  and an upper honeycomb layer  104 . In some instances, the intermediate layers  118  may be disposed between each of the honeycomb layers  102 ,  104 ,  106 ,  108  of the tiered structure  101 . The load structure  10  is generally shown having four honeycomb layers. The load structure  10  may include more or less than four honeycomb layers within the scope of the present disclosure. 
     Referring now to  11 B, in some example configurations, each honeycomb layer  102 ,  104 ,  106 ,  108  of the tiered structure  101  comprises a plurality of ribbons  109 . The ribbons  109  may include a plurality of cells  111  that form a honeycomb structure. The cells  111  may include shapes that are substantially polygonal (e.g., rectangular, hexagonal, etc.) or circular. The layers  102 ,  104 ,  106 ,  108  may be arranged such that the ribbons  109  of each respective layer are vertically aligned. For instance, first ribbons  109   1  of a first honeycomb layer (e.g.,  102 ,  106 ) may extend in a first vertical direction D 1  and second ribbons  109   2  of a second honeycomb layer (e.g.,  104 ,  106 ) may extend in a second vertical direction D 2 . The first and second ribbons  109   1 ,  109   2  may be vertically aligned such that the first vertical direction D 1  is parallel to and/or the same as the second vertical direction D 2 . 
     In some examples, the ribbons  109  of each respective honeycomb layer may be arranged in different horizontal orientations relative to one another, while still being vertically aligned. For example, first ribbons  109   1  of a first honey layer (e.g.,  102 ,  106 ) may be aligned in a first horizontal direction (e.g., D 3 ), and second ribbons  109   2  of a second layer (e.g.,  104 ,  106 ) may be aligned in a second horizontal direction (e.g., D 4 ). The first horizontal direction may be orthogonal to the second horizontal direction. In some examples, the ribbons  109  of each respective layer may be arranged in similar and/or the same horizontal orientations. For instance, the first horizontal direction may be parallel to and/or the same as the second horizontal direction. 
     With reference to  FIG. 11C , in some example configurations, the intermediate layers  118  may include a paper layer  110 , one or more adhesive layers  112  (e.g., a first adhesive layer  112   1 , a second adhesive layer  112   2 , and a third adhesive layer  112   3 ) and a fiberglass layer  120 . Collectively this arrangement forms a layered sandwich construction, wherein moisture is kept from transferring through the layered construction. 
     For example, and without limitation, a paper layer  110  may comprise one of a paper, a paper board (e.g., cardboard), or a kraft paper, among others. An adhesive layer (e.g.,  112   1-3 ) may comprise an adhesive material that may be water based or solvent based, and generally may be compatible with urethane, e.g., does not inhibit bonding of polyurethane to the paper, the inhibiting of bonding for which may result in fogging, odor, flammability, and the like. A fiber glass layer  120  may comprise a fiber-reinforced plastic including glass fiber, among others. 
     In some example configurations, a first adhesive layer  112   1  may be disposed between a first honeycomb layer (e.g.,  102 ) and a fiberglass layer  120 . The fiberglass layer  120  may be disposed between the first adhesive layer  112   1  and a second adhesive layer  112   2 . The second adhesive layer  112   2  may be disposed between a paper layer  110  and a third adhesive layer  112   3 . The third adhesive layer  112   3  may be disposed between the paper layer  110  and a second honeycomb (e.g.,  106 ). 
     In some configurations, a first adhesive layer  112   1  may be disposed between the second honeycomb layer (e.g.,  106 ) and a fiberglass layer  120 . The fiberglass layer  120  may be disposed between the first adhesive layer  112   1  and a second adhesive layer  112   2 . The second adhesive layer  112   2  may be disposed between a paper layer  110  and a third adhesive layer  112   3 . The third adhesive layer  112   3  may be disposed between the paper layer  110  and a third honeycomb layer (e.g.,  104 ). The purpose of the paper layer  110  is to stabilize one or more of the honeycomb layers, for example, during expansion and subsequent processes, provide a uniform bonding surface for an additional layer of honeycomb, and to distribute the compression load at forming to insure the deformation of the exterior honeycomb. 
     Referring now to  FIG. 11A , in some implementations, the intermediate layers  118  may be sized and located to cover, at least partially, one or more surfaces  122   1-6  of the respective honeycomb layers. For example, and without limitation, a first honeycomb layer (e.g.,  102 ) may include a first surface (e.g.,  122   1 ) that faces a second honeycomb layer (e.g.,  106 ), and the second honeycomb layer may include a second surface (e.g.,  122   2 ) that faces the first honeycomb layer. The first surface may be larger than the second surface (e.g., include a larger surface area). A plurality of intermediate layers  118  may be arranged and sized such as to cover an area of contact between the first and second honeycomb layers. The area of contact may include a size that is substantially equal to the size of the second surface. In some instances, exposed portions  130  of the first surface of the first honeycomb layer may not include the intermediate layers  118 . 
     The second honeycomb layer (e.g.,  106 ) may include a third surface (e.g.,  122   3 ) that faces a third honeycomb layer (e.g.,  106 ), and the third honeycomb layer may include a fourth surface (e.g.,  122   4 ) that faces the second honeycomb layer. The third surface may be larger than the fourth surface (e.g., include a larger surface area). A plurality of intermediate layers  118  may be arranged and sized such as to cover an area of contact between the second and third honeycomb layers. The area of contact may include a size that is substantially equal to the size of the fourth surface. In some instances, exposed portions  130  of the third surface of the second honeycomb layer may not include the intermediate layers  118 . 
     The third honeycomb layer (e.g.,  106 ) may include a fifth surface (e.g.,  122   5 ) that faces a fourth honeycomb layer (e.g.,  104 ), and the fourth honeycomb layer may include a sixth surface (e.g.,  122   6 ) that faces the third honeycomb layer. The fifth surface may be larger than the sixth surface (e.g., include a larger surface area). A plurality of intermediate layers  118  may be arranged and sized such as to cover an area of contact between the third and fourth honeycomb layers. The area of contact may include a size that is substantially equal to the size of the sixth surface. In some instances, exposed portions  130  of the fifth surface of the third honeycomb layer may not include the intermediate layers  118 . 
     In some example configurations, the intermediate layers  118  are arranged between adjacent honeycomb layers such as to restrict and/or prevent air flow between the adjacent honeycomb layers. For example, the intermediate layers  118  may be arranged between adjacent honeycomb layers such that the adjacent honeycomb layers are non-permeable and/or are not in fluid communication with one another. In some examples, the intermediate layers  118  are configured to aid in the bonding between the adjacent honeycomb layers. The intermediate layers  118  may add strength and/or rigidity to the tiered structure  101  such as to prevent undesirable crushing (e.g., deformation) of certain honeycomb layers  102 ,  104 ,  106 ,  108 . 
     Referring now to  FIG. 12 , an additional exemplary method  400  for manufacturing a multi-dimensional load structure (e.g., a load structure  10  as depicted in  FIGS. 8-10 ) is illustrated. The method  400  may include steps that are substantially similar to the steps of method  200 . The method  400  may include, but is not limited to, forming a tiered structure including providing a first honeycomb layer and a second honeycomb  402 , disposing a plurality of intermediate layers onto the first honeycomb layer or the second honeycomb layer  404 , disposing a second honeycomb layer onto the first honeycomb layer  406 , providing additional intermediate layers and/or honeycomb layers  408 , forming the tiered structure into a panel  410 , conducting a final trim process  412  to remove excess material, and providing a final assembly  414  such as adding hardware, etc. It will be appreciated that other steps may be deployed. 
     Method  400  may begin at step  402  in which a first honeycomb layer (e.g.,  102 ) and a second honeycomb layer (e.g.,  106 ) is provided. Step  402  generally may begin the process of forming a tiered structure  101  of the load structure  10 . For instance, the tiered structure  101  may be formed in a similar manner as in step  202  of method  200 , except for certain differences that are discussed below. 
     After step  402 , the method  400  may proceed to step  404  in which a plurality of intermediate layers  118  are disposed onto the first honeycomb layer or the second honeycomb layer. In some instances, the intermediate layers  118  may be disposed onto the first honeycomb layer and, in other instances, the intermediate layers  118  may be disposed onto the second honeycomb layer prior to first and second honeycomb layers being joined. 
     The intermediate layers may include one or more adhesive layers  112   1-3 , a fiberglass layer  120 , and a paper layer  110 . For example, and without limitation, a first adhesive layer  112   1  may be disposed (e.g., sprayed, rolled, injected, etc.) onto a surface (e.g.,  122   1 ) of the first honeycomb layer (e.g.,  102 ) or a surface (e.g.,  122   2 ) of the second honeycomb layer (e.g.,  106 ). 
     A fiberglass layer  120  may be disposed onto the first adhesive layer  112   1 . For example, the fiberglass layer  120  may be pulled from a roll of fiberglass and placed onto the first adhesive layer  112   1  and/or the fiberglass layer  120  may be in the form of a sheet that is placed onto the first adhesive layer  112   1 , among others. 
     A second adhesive layer  112   2  may be disposed onto the fiberglass layer  120 . The second adhesive layer  112   2  may be substantially similar to the first adhesive layer  112   1 . For instance, the second adhesive layer  112   2  may comprise the same adhesive and/or may be applied in the same manner as an adhesive of the first adhesive layer  112   1 . In some examples, the second adhesive layer  112   2  may include one or more different characteristic (e.g., thickness, material composition, size of surface area coverage, etc.) than the first adhesive layer  112   1 . Alternatively, the first adhesive layer  112   1  may be applied to a first side of the fiberglass layer  120  and/or the second adhesive layer  112   2  may be applied to second side of the fiberglass layer  120  prior to the fiberglass layer being disposed onto the first honeycomb layer or the second honeycomb layer. 
     A paper layer  110  may be disposed onto the second adhesive layer  112   2  and a third adhesive layer  112   3  may be disposed onto the paper layer  110 . The third adhesive layer  112   3  may be substantially similar to the first and second adhesive layers  112   1-2 . For instance, the third adhesive layer  112   3  may comprise the same adhesive and/or may be applied in the same manner as adhesives of the first and second adhesive layers  112   1-2 . In some examples, the third adhesive layer  112   3  may include one or more different characteristic (e.g., thickness, material composition, size of surface area coverage, etc.) than the adhesives of the first and second adhesive layers  112   1-2 . 
     Alternatively, the second adhesive layer  112   2  may be applied to a first side of the paper layer  110  and the third adhesive layer  112   3  may be applied to a second side of the paper layer  110  prior to the paper layer  110  being disposed onto the first honeycomb layer or the second honeycomb layer. In some examples, the paper layer  110 , the fiberglass layer  120 , and/or the adhesive layers  112   1-3  may be joined together prior to being disposed onto the first honeycomb layer or the second honeycomb layer. 
     After step  404 , the method  400  may proceed to step  406  in which the second honeycomb layer (e.g.,  106 ) is disposed onto the first honeycomb layer (e.g.,  102 ) such that the intermediate layers  118  are disposed between the first and second honeycomb layers. The second honeycomb layer may be disposed onto the first honeycomb layer such that the first and second honeycomb layers are vertically aligned. For instance, ribbons of the first honeycomb layer may be vertically aligned with ribbons of the second honeycomb layer. 
     After step  406 , the method  400  may proceed to step  408  in which additional intermediate layers  118  and/or honeycomb layers ( 104 ,  106 , etc.) may be disposed onto the second honeycomb layer. It should be appreciated that the number of honeycomb layers (e.g., lower honeycomb layers, upper honeycomb layers, and interior honeycomb layers) may be the same or may be different, as illustrated in the figures. For instance, the number of honeycomb layers depends upon the final desired shape and profile of the load structure  10 . 
     In some examples, step  408  may include providing a third honeycomb layer (e.g.,  104 ,  106 ). A plurality of intermediate layers  118  may be disposed onto the second honeycomb layer or the third honeycomb layer. The third honeycomb layer may subsequently be disposed onto the second honeycomb layer such that ribbons of the third honeycomb layer are vertically aligned with ribbons of the first and second honeycomb layers. 
     After step  408 , the method  400  may proceed to step  410  in which the tiered structure  101  may be formed into a panel. Step  408  may be substantially similar to and/or conducted in a similar manner as step  204  of method  200 . In some examples, a glass layer  114  may be applied to the panel  100 . The glass layer  114  may be applied to the panel  100  in a similar manner as step  206  of method  200 . In some instances, a coating  116  may be applied to the glass layer  114 . The coating  116  may be applied to the glass layer  114  in a similar manner as step  208  of method  200 . 
     After step  410 , the method  200  may proceed to step  412  in which the panel  100  may undergo final trimming. The panel  100  may be placed in a trim tool, which may be designed to remove any excess material such that the panel  100  is trimmed to the final footprint of the load structure  10 . Step  412  may be substantially similar to and/or conducted in a similar manned as step  210  of method  200 . 
     After step  412 , the method  400  may proceed to step  414 , during which the panel  100  may undergo final assembly, for example, by attaching a handle (e.g., handle  22 ), hardware, or other external feature(s) (e.g., fasteners  24 ) to the panel  100 . In some examples, the fasteners  24  may be added to the panel  100  prior to step  414 . For instance, the fasteners  24  may be added to the panel  100  during the forming the tiered structure  101 . In some instances, a portion of at least one of the fasteners may be disposed within and/or fixed to the panel. 
     With regard to the processes, systems, methods, heuristics, etc. described herein, it should be understood that, although the steps of such processes, etc. have been described as occurring according to a certain ordered sequence, such processes could be practiced with the described steps performed in an order other than the order described herein. It further should be understood that certain steps could be performed simultaneously, that other steps could be added, or that certain steps described herein could be omitted. In other words, the descriptions of processes herein are provided for the purpose of illustrating certain embodiments, and should in no way be construed so as to limit the claims. 
     It will be appreciated that the aforementioned method and devices may be modified to have some components and steps removed, or may have additional components and steps added, all of which are deemed to be within the spirit of the present disclosure. Even though the present disclosure has been described in detail with reference to specific embodiments, it will be appreciated that the various modifications and changes can be made to these embodiments without departing from the scope of the present disclosure as set forth in the claims. The specification and the drawings are to be regarded as an illustrative thought instead of merely restrictive thought. 
     All terms used in the claims are intended to be given their broadest reasonable constructions and their ordinary meanings as understood by those knowledgeable in the technologies described herein unless an explicit indication to the contrary in made herein. In particular, use of the singular articles such as “a,” “the,” “said,” etc. should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary.