Patent ID: 8784605

Claim:
A process for making lightweight laminated panel material for construction of cargo containers, comprising: providing an inner core high performance fabric layer having a first side and a second side; disposing a first film adhesive layer on the first side of the core high performance fabric layer; disposing a second film adhesive layer on the second side of the core high performance fabric layer; disposing a first protective surface film layer over the first film adhesive layer; disposing a second protective surface film layer over the second film adhesive layer, said inner core high performance fabric layer, said first film adhesive layer, said second film adhesive layer, said first protective surface film layer, and said second protective surface film layer forming a pre-lamination stack, wherein said first and second protective surface film layers are formed from a material selected from the group consisting of polyurethane film, metallized polyurethane film, nylon film, and metallized nylon film; disposing a first release layer over said first protective surface film layer; disposing a second release layer over said second protective surface film layer; heating said pre-lamination stack and said first and second release layers to a predetermined temperature, wherein said predetermined temperature is above a bond line temperature of the film adhesive layers; compressing said pre-lamination stack under a predetermined pressure; maintaining said pre-lamination stack at said predetermined temperature and under said predetermined pressure for a predetermined period of time to form a lamination stack; cooling the lamination stack to a temperature below approximately 160° F. while maintaining said pre-lamination stack under said predetermined pressure; releasing said predetermined pressure from the lamination stack; cooling the lamination stack to room temperature; and removing said first and second release layers.