Patent Application
20140199525
1. The Field of the Invention
This invention relates to apparatus, systems, and methods for panels that can be used as a ceiling, wall, or floor structure, or as a treatment thereto.
2. Background and Relevant Art
Recent trends in building design involve using one or more sets of decorative panels to add to the functional and/or aesthetic characteristics of a given structure or design space. These recent trends are due, at least in part, because there is sometimes more flexibility with how the given panel (or set of panels) is designed, compared with the original structure. For example, recent panel materials include synthetic, polymeric resin materials, which can be formed as panels to be used as partitions, walls, barriers, treatments, décor, etc. Examples of such resin materials include polyvinyl chloride or “PVC”; polyacrylate materials such as poly (methyl methacrylate) or “PMMA”; polyester materials such as poly (ethylene-co-cyclohexane 1,4-dimethanol terephthalate), or “PET”; poly (ethylene-co-cyclohexane 1,4-dimethanol terephthalate glycol) or “PETG”; glycol modified polycyclohexylenedimethlene terephthalate; or “PCTG”; as well as polycarbonate (or “PC”) materials.
In general, resin materials such as these are now popular compared with decorative cast or laminated glass materials, since resin materials may be manufactured to be more resilient and to have a similar transparent, translucent, or decorative appearance as cast or laminated glass, but with less cost. Decorative resins can also provide more flexibility compared with glass at least in terms of color, degree of texture, gauge, impact resistance, and ease of fabrication.
One particular type of resin panel that is now popular is honeycomb core panels. Honeycomb core panels include a honeycomb core bonded between two outer sheets or skins. Such panels are popular because the core reduces the overall weight of the panel, while also increasing the strength of the panel. Furthermore, the honeycomb core can provide a unique aesthetic.
One conventional mechanism for creating honeycomb core laminate panels can involve adhering a honeycomb core between two substrates with an adhesive. The adhesive may be liquid at the time of application, which allows the honeycomb core and substrates to bond together with relative immediacy. To apply the adhesive, the manufacturer may spread (e.g., with one or more rollers) or spray a liquid adhesive on both sides of a honeycomb core or to a single side of one or more substrate panels, or skins, and then press such panels directly against the honeycomb core. Such liquid laminations, however, may be relatively weak in the context of building materials. In particular, such liquid laminations can have a greater risk of delamination since the bond strength can be primarily determined by uniformity of the liquid adhesive application, which is susceptible to bubbles, voids, debris, and relies on chemical bonding.
In other cases, a manufacturer can utilize a solid resin film adhesive. For example, the manufacturer first adheres, laminates, or attaches a solid adhesive resin film on one side of one or more substrate panels. The manufacturer then performs a second step of adhering the substrate panels to both sides of the honeycomb core. The adhesion is achieved via the application of heat (and, also pressure in some cases), which causes the adhesive resin film to become tacky, and bond the honeycomb core and substrates together albeit with a primarily chemical bond.
As with the liquid adhesive, applying a solid adhesive may not necessarily form a sufficiently strong bond between the substrates and the honeycomb core for use as a building material. Also, similar to a liquid adhesive, the strength of solid adhesives can be dependent upon a uniform bond and a lack of bubbles, voids, and debris. Furthermore, with a film adhesive that needs heat and pressure to melt and form the ensuing bond, there is a risk of the processing temperatures (and pressures in some cases) will melt the substrates and/or honeycomb core. This risk is enhanced when the resin adhesive layer, the substrates, and honeycomb core comprise similar resin materials with similar melting/glass transition temperatures. Lastly, solid adhesives tend to be expensive and the additional processing steps associated therewith increase the chances for reduced product yield due to entrapped contaminants (dirt, debris, air, etc) to the exposed adhesive portion of the skin material.
Implementations of the present invention solve one or more of the foregoing or other problems in the art with systems, methods, and apparatus configured to efficiently produce structured-core laminate panels. Specifically, implementations of the present invention comprise apparatus and methods for laminating one or more resin substrate panels to one or more structured core members using primarily heat and pressure that selectively melts or softens some components (at least in part) but not others. In at least one implementation, a manufacturer can create a structured-core laminate panel with sufficient structural properties for use as a building material, optionally without the use of any adhesives. In particular, the manufacturer can create a solid structure in which the resin substrates are melted and bonded to a structured core.
For example, one implementation of a method of manufacturing a structured-core laminate panel can involve preparing an assembly. The assembly can include one or more resin substrates having at least a first glass transition temperature positioned about at least one structured core member having at least a second melt or glass transition temperature. The first glass transition temperature can be lower than the second melt or glass transition temperature.
The method can also involve heating the assembly to a processing temperature at least as great as the first glass transition temperature but below the second melt or glass transition temperature, wherein a portion of the one or more resin substrates flows around the structured core member. Additionally, the method can involve cooling the assembly below the first glass transition temperature to create a structured-core laminate panel. The one or more resin substrates can thereby bond to the structured core member such that the structured core member is embedded within the structured-core laminate panel. Furthermore, the one or more resin substrates can bond to the structured core member without substantial deformation of the structured core member, and/or without the use of an adhesive film between the one or more resin substrates and the structured core.
An implementation of a structured-core laminate panel can comprise at least one resin substrate having a first glass transition temperature, and at least one structured core member embedded within the at least one resin substrate. The at least one structured core member can comprise a channel having at least one opening and can have a second melt or glass transition temperature that is higher than the first glass transition temperature. At least a portion of the at least one resin substrate can be bonded to and around the structured core, and the channel can be oriented relative to the resin substrate such that the at least one opening of the channel is positioned at an end of the resin substrate such that the channel provides a conduit into or through the resin substrate.
Furthermore, a panel system configured for use as a partition that provides both light transmission and privacy can include one or more structured-core laminate panels. The one or more structured-core laminate panels can include one or more resin substrates having a first glass transition temperature. Additionally, the one or more structured-core laminate panels can include one or more structured cores having a second melt or glass transition temperature that is greater than the first glass transition temperature. Moreover, at least a portion of the one or more resin substrates can be bonded to and around the one or more structured cores such that the one or more structured cores are embedded within at least a portion of the one or more resin substrates. Furthermore, at least one of the one or more structured cores can comprise a channel having at least one opening at a first end thereof. The channel can be oriented relative to the one or more resin substrates such that the opening is positioned at an end of the one or more resin substrates such that the channel provides a conduit into or through the one or more resin substrates. The panel system can also include a mounting system that secures the one or more translucent structured-core laminate panels to a support structure. Similarly, the channels within the panels could be used to relay electrical conduit, lighting elements or even transfer liquids or air through the structured panel.
Additional features and advantages of exemplary implementations of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of such exemplary implementations. The features and advantages of such implementations may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of such exemplary implementations as set forth hereinafter.
In order to describe the manner in which the above-recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It should be noted that the figures are not drawn to scale, and that elements of similar structure or function are generally represented by like reference numerals for illustrative purposes throughout the figures. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
The present invention extends to systems, methods, and apparatus configured to efficiently produce structured-core laminate panels. Specifically, implementations of the present invention comprise apparatus and methods for laminating one or more resin substrate panels to one or more structured core members using primarily heat and pressure that selectively melts or softens some components (at least in part) but not others. In at least one implementation, a manufacturer can create a structured-core laminate panel with sufficient structural properties for use as a building material, optionally without the use of any adhesives. In particular, the manufacturer can create a solid structure in which the resin substrates are melted and bonded to a structured core.
In general, and as understood more fully herein, a manufacturer can use resin materials that have different glass transition temperatures to melt the interface layers of the resin substrate(s) adjacent a polymer-based structured core (e.g., honeycomb cellular structure). Specifically, the manufacturer uses a structured core (having cells with any number of different sizes and formations/alignments) prepared from a polymer-based material having relatively high glass transition temperature, and one or more resin sheets having a relatively low glass transition temperature. In at least one implementation, the relatively high glass transition temperature material comprises polycarbonate, and/or composites or mixtures thereof. By contrast, in at least one implementation, the relatively low glass transition temperature material of the resin substrate(s) used in lamination comprises a copolyester material, acrylic material, and/or composites or mixtures thereof.
The difference in melt or glass transition temperatures between the resin substrates and the structured core can allow a manufacturer to heat and press a portion of the resin substrates into the cells of the structured core without melting or otherwise compromising the structure or strength of the structured core. Upon cooling, portions of the resin substrates within the structured core can form a mechanical bond unifying the resin substrates and the structured core. In some implementations, in addition to the mechanical bond, a chemical bond can form between the resin substrates and the structured core.
In any event, the bond between the resin substrates and the structured core can be stronger than chemical bonds formed by adhesives. Furthermore, in some implementations, the strength of the bond is independent of uniformity or a lack of bubbles, voids, and debris. Thus, implementations of the present invention can allow for repeated formation of structurally sound panels without the risk of panels with a defective bond.
Implementations of the present invention can thus produce strong and aesthetically pleasing structured-core laminate panels. In particular, structured-core laminate panels of the present invention can be lightweight due to the cellular structured-core, yet durable and strong. In particular, structured-core laminate panels of the present invention can have load-bearing characteristics and properties sufficient to allow manufacturers to use the panels as building materials. In particular, structured-core laminate panels of the present invention can be sufficiently strong to avoid delamination even under extreme conditions, such as dynamic and static loads, wide fluctuations in temperature, peeling forces or forceful impacts.
Additionally, as mentioned previously, in addition to excellent structural properties, structured-core laminate panels of the present invention can also provide unique and desirable aesthetics. For example, implementations of structured-core laminate panels can be translucent and allow light transmission there through. Designers can use such translucent structured-core laminate panels in lighting applications, such as light boxes, or as window coverings. Furthermore, the structured core and/or colors of the panels can provide varying degrees transparency/translucency, and thus, varying degrees of privacy. Thus, designers can use structured-core laminate panels of the present invention as partitions, doors, or dividers where varying degrees of privacy are desired.
Accordingly, and as will be appreciated more fully from the following specification and claims, a structured-core laminate panel in accordance with an implementation of the present invention can have aesthetic and functional versatility, and function in a wide variety of installations. In particular, designers can use the structured-core laminate panels described herein in any number of ceiling, floor, or wall applications, whether in indoor or outdoor environments, including any residential, commercial, or industrial environments. For example, structured-core laminate panels described herein can serve a primarily functional or structural use as a building component. In addition, the structured-core laminate panels described herein can function primarily for aesthetic/decorative use, such as to apply a particular look, and/or texture to a wall, column, or lighting element/arrangement in an interior or exterior space.
Referring now to the Figures,
As used herein, the terms “resin-based substrate,” “resin substrate,” “polymer-based substrate,” “polymer substrate,” “resin-based sheet” or “resin sheet” means a substrate comprising materials of one or more layers or sheets formed from any one of the following thermoplastic polymers (or alloys thereof). Specifically, such materials include but are not limited to, polyethylene terephthalate (PET), polyethylene terephthalate with glycol-modification (PETG), acrylonitrile butadiene-styrene (ABS), polyvinyl chloride (PVC), polyvinyl butyral (PVB), ethylene vinyl acetate (EVA), polycarbonate (PC), styrene, polymethyl methacrylate (PMMA), polyolefins (low and high density polyethylene, polypropylene), thermoplastic polyurethane (TPU), cellulose-based polymers (cellulose acetate, cellulose butyrate or cellulose propionate), or the like. Furthermore, the resin substrates can include other thermoplastic polymers or thermoplastic polymer blends, or combinations and mixtures thereof. In addition, any given resin substrate or sheet can include one or more resin-based substrates and any number other layers or coatings.
For example, the structured-core laminate panel 100 shown in
For example, in some implementations, the gauge of the structured-core laminate panel 100 in at least one implementation can be anywhere from about one-sixteenth inch ( 1/16″) to about two inches (2″) inches. The thickness of the structured-core laminate panel 100 can be based at least partially on the number of resin-based substrates it comprises, as well as the desired end-use. Furthermore, when upper 104a and lower 104b resin substrates are used, as in the structured-core laminate panel 100 of
In any event, the resin substrates 104 can include thermoplastic materials that a manufacturer can heat sufficiently above their glass transition temperature to soften, and then subsequently cool to solid form. More specifically, the resin substrates 104 can have a glass transition temperature lower than the melt or glass transition temperature of the structured core 102. Thus, one will appreciate that a manufacturer can select the thermoplastic materials of the resin substrates 104 based upon the materials of the structured core 102, or vice versa. As explained in greater detail below, the differences in melt or glass transition temperatures between the resin substrates 104 and the structured core 102 can allow a manufacturer to soften and press a portion of the resin substrates 104 into the cells 108 of the structured core 102 without melting or otherwise compromising the structure or strength of the structured core 102.
As used herein, the term “structured-core” means a structure including a plurality of cells or hollow chambers. For example, the structured-core 102 of
The structured core 102 can comprise thermoplastic materials, such as those previously mentioned in relation to the resin substrates 104. In alternative implementations, the structured core 102 can comprise glass, metal or other materials. Thus, the structured core 102 can comprise a wide variety of materials so long as the structured core has a higher melt or glass transition or melting temperature than that of the outer, adjacent resin substrate(s) 104. As mentioned previously, the higher melt or glass transition or melting temperature of the structured core 102 can ensure that a manufacturer can soften or melt the resin substrates 104 sufficiently to press a portion of the resin substrates into the structured core 102, without softening (at least not in a damaging way) the structured core 102.
In any case, in at least one implementation, the resin substrates 104a, 104b and/or the structured core 102 (or both) can be substantially translucent or transparent. Indeed in some implementations, at least the structured core 102 is substantially translucent, such that a significant amount of light can pass through the structured-core laminate panel 100. As previously mentioned, a manufacturer can use such translucent structured-core laminate panels 100 in lighting applications or as a semi-private divider. In alternative implementations, the resin substrates 104a, 104b and/or the structured core 102 (or both) can be opaque.
For example,
Furthermore, the resin-based substrates 104a, 104b can be any appropriate thickness for the resulting thickness of a final structured-core laminate panel 100, such as about two inches (2″), about one inch (1″), about one-half inch (½″), about one-fourth inch (¼″), about one-eighth inch (⅛″), about one-sixteenth inch ( 1/16″), or about one-thirty-second inch ( 1/32″) in thickness or gauge as desired. In some implementations of the present invention, the opposing resin substrates 104a, 104b can have similar thicknesses as shown in
Additionally, the size (i.e., surface area of sides 106 or 110) of the resin-based substrates 104a, 104b can also be any appropriate size for the desired size of resulting structured-core laminate panel 100. In at least one implementation, for example, the resin-based substrate 104a, 104b can be about four feet by about eight feet (4′×8′), about four feet by about ten feet (4′×10′), about six feet by about fifteen feet (6′×15′), or taller/wider. Or alternatively, the resin-based substrate 104a, 104b can be about six inches by about six inches (6″×6″) or shorter/skinnier. Thus, a manufacturer can tailor both the gauge and size of the resin-based substrate 104a, 104b depending upon the desired dimensions of a resulting structured-core laminate panel 100.
The structured core 102 can have any size relative to the size (i.e., surface area) as the surfaces 106 of the resin-based substrates 104a, 104b. For example,
In some cases, the manufacturer may also include other decorative items between or on the outer surfaces 110 of the resin substrate substrate(s) 104a, 104b in order to add any number of decorative effects. For example,
One will appreciate that there are a wide variety of decorative image layers that a manufacturer can add to the laminate assembly 120a to create a wide variety of effects. For example, the decorative image layer can comprise fabric, metallic wire, rod and/or bar, papers or printed or photographic images, crushed glass, and vegetation, such as wood chips, grasses, flowers, wheat, and thatch. The decorative image layer may display images or decorative designs or may be of a solid color. The melting point of the decorative image layer should be sufficiently high to avoid any degradation or distortion of the decorative image layer during the manufacture or processing of the laminate assembly. In some implementations, the decorative image layer(s) 122 is substantially continuous, and constitutes a distinct image layer or laminate, such as the decorative image layer 122 in
As shown in
Combination through lamination or adhesion of such film layers of differing colors creates a uniform colored panel that is a composite color of the individual film colors used to construct the laminate assembly 120a. Furthermore, so long as the colors selected are effectively transparent, the color ordering of colored films is not important as the color and hue of the panel remains the same throughout the finished panel regardless of viewing direction and ordering of the films on or within the resin substrates 104. In addition to varying the color of a resulting structured-core laminate panels 100, a manufacturer can use the decorative image layer 122 (and any films making up the decorative image layer 122) to vary the hue and/or translucency of a resulting structured-core laminate panel 100.
Additionally, the decorative image layer 122 need not necessarily be between two outer resin substrates 104b and 104c. For example, in at least one implementation, a manufacturer can position the decorative image layer 122 between the substrate 104b and/or 104a so that the decorative image layer 122 interfaces between the structured core 102 and the resin substrate(s) 104a, 104b. In further implementations, the manufacturer can apply the decorative image layer 122 directly to the outside surface 110 of substrate 104a (and/or 104b), as shown, but omit the third resin substrate 104c (or any other possible additional substrates 104—not shown). In either case, the manufacturer can achieve essentially the same color result in the resulting structured-core laminate panel 100.
Still further, one will appreciate that the manufacturer can construct the laminate assembly 120, 120a with a wide range of thermoplastic materials, which provide suitable properties in accordance with implementations described herein. In one implementation, for example, the manufacturer can use a structured core 102 comprised of polycarbonate materials, but use resin substrates 104 comprising glass transition temperatures that are lower than that for polycarbonate. Such lower glass transition temperature materials used in resin substrates 104 can comprise of any number of thermoplastic sheet materials including copolyesters, acrylic materials, and/or mixtures thereof.
In one implementation, in particular, the manufacturer prepares a laminate assembly 120, 120a with a polycarbonate structured core 102, and further with acrylic materials as the next adjacent resin substrate(s) 104a or 104b. The manufacturer can further use a colored film layer as a decorative layer 122 adjacent the acrylic layer 104a or 104b, whereby the thin colored film decorative layer 122 comprises colorant loaded acrylic films (although other colored thin films such as EVA or TPU may be utilized). In this implementation, the manufacturer can also optionally use another outer layer 104c, though this is not required for all implementations. In such a case, the other outer layer 104c adjacent the colored film decorative layer 122 can comprise a thermoplastic sheet such as acrylic or copolyester (e.g., PETG), or mixtures thereof.
In another implementation, the manufacturer prepares a laminate assembly 120, 120a with a polycarbonate structured core 102, and further uses acrylic or copolyester uniformly for all of the resin substrate layers 104a, 104b, and/or 104c, and the colored film decorative layer 122. In still further implementations, the manufacturer prepares a laminate assembly 120a using all three (or more) illustrated substrates 104a, 104b, and 104c (or more than those illustrated), and further applies a colored film decorative layer 122 to the outside thereof (e.g., on the outer surface 110 of substrate 104c).
In addition to the foregoing, the manufacturer may apply other components to the laminate assembly as may be required for applying temperature and pressure. In one implementation using conventional heat presses (thereby utilizing mechanical pressure and conductive heating and cooling), for example, the manufacturer can surround the sheet laminate assembly with one or more pressure pads, one or more metal plates, and/or one or more texture papers (to impart still further aesthetic effects). The pressure pads and/or metal plates can equalize pressure and temperature across the entire surface of the laminate assembly 120, 120a. By contrast, the texture papers can impart any number of different textures or glosses on the resin substrates 104 during lamination.
Upon preparing the laminate assembly 120, 120a, the manufacturer then applies appropriate heat and pressure to form a structured-core laminate panel 100. In at least one implementation, the manufacturer applies enough heat and pressure to cause the one or more resin substrates 104a, 104b to melt at the interface with the structured core 102, without causing the structured core 102 to melt or deform. Furthermore, the temperature and pressure can be sufficient to avoid causing any deformation in the outer surfaces 110 of the resin substrates 104a, 104b, 104c, such as any dimpling due to collapse on an opposing side of the resin substrate 104 into any particular cell/chamber 108.
In particular, the manufacturer can heat the sheet assembly 120, 120a to a processing temperature sufficient to soften or at least partially melt the resin substrates 104, but not high enough to soften or melt the structured core 102. Thus, the manufacturer can heat the sheet assembly to a processing temperature at least as great as the glass transition temperature of the resin substrate(s) 104, but below the melt or glass transition temperature of the structured core 102. Along related lines, the manufacturer can apply a processing pressure to the laminate assembly 120, 120a sufficient to cause softened or melted resin of the resin substrates 104a, 104b to flow into the cells 108 of the structured core 102, but not so great as to damage the structured core 102.
In at least one implementation, the processing temperature is between about 180° F. and about 295° F. One will appreciate that varying resins can have a wide range of glass transition temperatures, and thus, the processing temperature can vary depending on which resins are used. For example, in an implementation using a polycarbonate structured core 102 and copolyester (e.g., PETG, PET, and PCTG) resin substrates 104, the appropriate processing temperature may be between about 180° F. to about 275° F. Alternatively, when using a polycarbonate structured core 102 and acrylic (e.g., PMMA) resin substrates 104, the appropriate processing temperature may be between about 190° F. to about 295° F., depending largely on the applied pressure.
For example, in at least one implementation, the manufacturer can implement a processing pressure that is between approximately 5 pounds per square inch (psi) and approximately 250 psi, and preferably between about 5 psi and about 50 psi for each such material. In an implementation in which the structured core 102 comprises polycarbonate and the opposing resin substrate(s) 104 comprise a copolyester material, the appropriate pressure can be about 40 psi.
As discussed herein, the structured core 102 in implementations of the present invention does not deform in any appreciable way since the above-mentioned temperatures do not elevate the materials of the structured core 102 to its melt or glass transition temperature (i.e., polycarbonate has a glass transition temperature that is usually achieved at temperatures higher than 300° F.). Similarly, the noted temperatures and pressures of the present invention do not elevate the materials of the structured core 102 to heat distortion temperatures. At a pressure of about 66 psi, the heat distortion temperature for a polycarbonate structure would be about 280° F. Of course, however measured, the primary point in at least one implementation is that the polycarbonate structured core 102 will not be at its glass transition temperature or heat distortion parameter(s), even if the adjacent resin substrate(s) 104 is at such parameters.
One will appreciate that a manufacturer can apply the processing temperature(s) and pressure(s) to the laminate assembly 120, 120a to form a structured-core laminate panel 100 in any number of different apparatus. For example, in some implementations the manufacturer can place the laminate assembly 120, 120a within a thermosetting press. In general, the thermosetting press can include upper and lower platens configured to provide direct heat and pressure to both opposing sides of the given laminate assembly 120, 120a.
In addition to the foregoing, implementations of the present invention further include using an autoclave to apply the processing temperatures and pressures. For example, the manufacturer can place the laminate assembly 120, 120a into a vacuum bag. The manufacturer can then seal the edges of the vacuum bag, and remove air from the vacuum bag. The manufacturer can then place the vacuum bag within the autoclave, which applies equal heat and pressure in all directions on the laminate assembly 120, 120a. In general, an autoclave can heat the laminate assembly 120, 120a (e.g., via a convection process, rather than via conduction as with a mechanical press) with a controlled temperature profile.
One will appreciate that the autoclaving process can provide a number of additional benefits for creating an appropriate, aesthetically pleasing, structured-core laminate panel 100. For example, autoclaving is typically not constrained to one size/format (i.e., an autoclave can process a 2′×4′ piece at the same time as an 8′×10′ piece). In addition, in the autoclaving process, pressure can be continuous throughout heating and cooling cycles. This continuous pressure can keep the laminate assembly 120, 120a flat throughout the heating and cooling cycles, which can eliminate bowing. Further along these lines, autoclaving is a convective heating process that allows for more controlled heating and cooling at each direction about the sublimation assembly, and thus allows for equal temperatures at the same depth throughout each corresponding substrate's thickness. Again, since the temperature, and pressure, is uniformly distributed throughout each substrate, the autoclave can process multiple different sublimation assemblies without any warping/bowing, etc.
In addition to an autoclave process, yet another implementation for heating and pressurizing a laminate assembly 120, 120a can include use of a vacuum press. In particular, and as previously mentioned with respect to the autoclave process, a manufacturer can prepare a vacuum bag with a laminate assembly 120, 120a therein. The manufacturer can then position the vacuum bag into a vacuum press, and apply the appropriate processing temperatures and pressures. In another implementation, a manufacturer can place a laminate assembly 120, 120a (without a vacuum bag) in a vacuum press chamber, where air is evacuated prior to application of mechanical pressure.
In any event, during this time interval, the resin substrates 104a, 104b begin to flow, particularly at the inner surfaces 106 abutting the structured core 102. As discussed, this generally occurs since the temperatures and pressures are sufficient to cause the resin substrate materials to meet or exceed their respective glass transition temperatures. As shown in
In addition, in implementations including a decorative image layer 122, such as a color film layer, and additional outer resin substrate(s) 104c, the processing temperatures and pressures will cause the outer surface 110 of the resin substrate 104c and the inner surface 106 of the resin substrate 104a to soften, become tacky and bond to the decorative image layer 122, and/or each other. In at least one implementation, such as where the resin substrate layers 104a and/or 104b, and 104c are translucent, the resin substrate layers 104 will substantially exhibit the color of the color film, often without any clear visual evidence of the presence of the color film in the final structured-core laminate panel 100.
As previously mentioned, manufacturers can modify implementations of the present invention in any number of ways to achieve a wide range of functional and/or aesthetic effects. In at least one implementation of the present invention, for example, the structured-core laminate panel 100 comprises one or more at least partly translucent resin substrates. The resin substrates can further comprise coloration in one form or another, such as by further including any dyes during the resin extrusion process, or by laminating still further colored films directly to the substrates (before, during, or after lamination with the structured core). In addition, one will appreciate that the structured cores themselves can be varied for a wide range of functional and/or aesthetic effects. For example, the structured cores can be varied in terms of size, pattern, cell geometry, spacing, depth, thickness, color, material, and translucence.
For example,
As shown by
Furthermore,
For example,
Furthermore, one will appreciate that the cells of the structured-core laminate panel 100c can provide a unique aesthetic. As mentioned previously, the cells of the structured core can have a wide variety of shapes and configurations. Additionally, the cells 108 of a particular structured-core laminate panel need not be uniform. For example,
One will appreciate that a manufacturer can design or configure the structured core to provide varying degrees of privacy. Thus, the structured-core laminate panel 100b can function as a partition that provides both light transmission and privacy. Indeed, a manufacturer can modify the color and opacity/translucence of the structured-core laminate panel 100b in any number of ways to adjust the opacity/transparency of the structured-core laminate panel 100b for desired aesthetic effect. For instance, in at least one implementation, a manufacturer can modify the hue, color intensity, and light transmission of the structured core and/or the decorative image layer 122 to vary the resultant aesthetic properties of the structured-core laminate panel 100b. Accordingly, one will appreciate that implementations of the present invention provide a manufacturer with a number of ways to prepare a structurally useful, aesthetically desirable panel. These panels can have a wide range of shapes, sizes, thicknesses, properties or colors, and can be used in a wide range of environments and applications.
Accordingly,
For example,
In addition,
As noted above, implementations of the present invention can include a structured core laminate panel comprising one or more resin substrates having one or more types of structured core members embedded therein. In addition to that noted above, for instance, certain types of structured cores can include one or more structured tubes, channels, passageways, reservoirs, cells, or hollow chambers around or about which softened or melted resin of the resin substrates is or has been bonded, and however oriented. Specifically, the structured core members can include cylindrical, rectangular, geometric or other tubular structured channels, which are embedded in and oriented parallel to the elongated structure of the resin substrate or panel, such that the channel provides a conduit into or through the panel. Such embedded channels may be configured to provide structural support for the panel through the prevention or reduction of creeping or other deformation.
In at least one implementation, the channel is (further) configured to receive one or more decorative, artistic, aesthetic, or functional feature(s) or other objects and/or the resin-based panel comprises non-opaque (transparent or translucent) material(s) that allows the object(s) within the embedded channel to be observed through a surface of the panel. Such features and/or objects may contribute properties such as color, texture, movement, dynamic motion, shade, privacy, advertisement, or other characteristics.
As illustrated in
For instance, a channel 102b according can be configured such that a first opening of the channel is exposed on an end side of a panel, while a second opening of the channel is exposed on a surface, viewing surface, or face side 107 of the panel 100b. A channel according to the present invention may also extend from a first portion of a first end of the panel to a second portion of the first end of the panel without departing from the scope of the present invention. In addition, a channel may extend only partially into, but not (entirely) through a panel such that the channel comprises a single opening or orifice, or has no accessible opening at all. For example, the structured core 102b can comprise an elongate tube oriented parallel to the resin substrates 104a-b, but be completely contained and enveloped there between without access to the opening or orifice.
In at least one illustrative implementation, structured tubes comprise polycarbonate materials, and resin substrates comprise material(s) with glass transition temperatures that are lower than that for polycarbonate. Such lower glass transition temperature material(s) can comprise any number of thermoplastic material(s) or thermoplastic sheet material(s) including co-polyesters, acrylic materials, and/or mixtures thereof. One will appreciate, however, that the use of polycarbonate is illustrative only and that the present invention is not so limited.
In certain implementations, the one or more resin substrates comprise at least a first material(s), and the one or more structured cores or channels comprise at least a second material(s), wherein the second material(s) is more resistant to creeping than the first material(s). Accordingly, the laminate panel is at least partially reinforced and/or prevented from creeping, bowing, bending, or otherwise deforming because of the embedded channel(s).
One or more implementations of the present invention further comprise methods of manufacturing panels including embedded channels, including those oriented essentially parallel to the substrate. Specifically, at least one implementation of the present invention comprises a method for laminating one or more resin substrate(s) or substrate panel(s) to or around one or more channel(s) using primarily heat and pressure that selectively melts some components (at least in part) but not others, forming a resin-based panel including embedded channel(s). The difference in melt or glass transition temperatures between the resin substrates and the channel can allow a manufacturer to heat and press at least a portion of the resin substrate(s) onto the structured channel without melting or otherwise compromising the structure and/or strength of the structured channel.
The method can also include heating the assembly 120b to a processing temperature T. In certain implementations, processing temperature T is at least as great as the first glass transition temperature but below the second melt or glass transition temperature. For instance,
In at least one implementation, the method can also include exerting or applying a force or pressure P on or to the laminate assembly 120b. Specifically, as illustrated in
Similarly, the method can also include actively or passively cooling the assembly 102b below the first glass transition temperature to create a structured-core laminate panel 100c. In certain implementations, the one or more resin substrates 104 are thereby bonded to the one or more structured cores or tubes 102b without substantial deformation of the one or more structured cores or tubes 102b. For instance, in
It will also be appreciated, however, that other implementations of the present invention can involve partially deforming the structured channel member(s) 102b. Additionally, other implementations can include the use of an adhesive or adhesive film between the one or more resin substrates and/or the between the one or more structured channel members and the one or more resin substrates.
One will also appreciate that a manufacturer can apply the processing temperatures T and pressures P to the laminate assembly to form a structured laminate panel with and/or in any number of different apparatus. For example, in one or more implementations the manufacturer can place the laminate assembly within a thermosetting press, an autoclave, a vacuum press, or any other thermosetting apparatus.
In addition, one or more additional resin substrates can be incorporated into laminate assembly 120c to form panel 100c. As illustrated in
In some implementations, additional resin substrates 104c can melt, soften, move, and/or flow around the one or more structured cores or channels 102b. For instance,
In at least one implementation, the one or more resin substrates can be coupled, bonded, or adhered to each other or to the one or more additional substrates with an adhesive. The adhesive can be liquid, semi-solid, or solid at the time of application. The method can involve spreading, spraying, or otherwise applying an adhesive on or to a side or surface of one or more substrates.
The figures and methods described herein provide a number of unique products, as well as ways for creating aesthetically pleasing, decorative, architecturally-suitable panels with structured cores or channels embedded therein. Such channels can be configured to substantially prevent or reduce panel deformation and/or to receive decorative, structural, and/or other objects. As discussed herein, these panels can be substantially translucent or transparent in order to provide a desired aesthetic and visual access to object(s) contained within or passing through or into a channel. Alternatively, panels can be substantially opaque in order to at least partially hide or otherwise disguise object(s) and/or mounting or suspending hardware within the channel(s) of the panel. Furthermore, certain implementations of the present invention provide methods of bonding or embedding a structured channel to or within one or more resin substrates without damaging or degrading channels or structured core during processing.
Accordingly, the schematics and methods described herein provide a number of unique products, as well as ways for creating aesthetically pleasing, decorative, architecturally-suitable panels with structured cores. As discussed herein, these panels can be substantially translucent or transparent in order to provide a desired aesthetic. Furthermore, the implementations of the present invention provide methods of bonding a structured core to one or more resin substrates without damaging or degrading the structured core during processing. Accordingly, implementations of the present invention can create not only a structured-core laminate panel with pleasing aesthetics, but also a panel that is sufficiently strong to avoid delamination even under extreme conditions.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
The present application is a continuation-in-part of U.S. patent application Ser. No. 13/318,771, filed Nov. 3, 2011, entitled “Structured-Core Laminate Panels and Methods of Forming the Same,” which is the national stage application of PCT/US 10/34349, filed May 11, 2010, entitled “Structured-Core Laminate Panels and Methods of Forming the Same,” which claims the benefit of priority to U.S. Provisional Application No. 61/177,939, filed May 13, 2009, entitled “Laminated Structured-Core Panels.” The present application also claims the benefit of priority to U.S. Provisional Application No. 61/792,228, filed Mar. 15, 2013, entitled “Architectural Panels Including Embedded Channels and Methods of Forming the Same.” The present application is also a continuation-in-part of PCT/US12/59824, filed Oct. 12, 2012, entitled “Resin Panels with Embedded Structured-Cores and Methods of Making the Same,” which claims the benefit of priority to U.S. Provisional Application No. 61/546,456, filed Oct. 12, 2011, entitled “Unitary Structured Core Panels.” The entire content of each of the aforementioned patent applications is incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 61177939 | May 2009 | US | |
| 61792228 | Mar 2013 | US | |
| 61546456 | Oct 2011 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13318771 | Nov 2011 | US |
| Child | 14211474 | US | |
| Parent | PCT/US12/59824 | Oct 2012 | US |
| Child | 13318771 | US |
