Patent Application
20150140252
1. The Field of the Invention
This invention relates to apparatus, methods, and systems for laminate panels produced from existing resin portions, such as, for example, recycled waste trimmings resulting from the production of other laminate panels.
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 of design space. For instance, some recent architectural designs have implemented synthetic thermoplastic polymeric resin panels for use as partitions, displays, barriers, lighting diffusers, decorative finishes, etc. Polymeric resin panel materials may include, for example, poly vinyl chloride (PVC); polyacrylate materials such as poly (methyl methacrylate) (PMMA); polyester materials such as poly (ethylene-co-cyclohexane 1,4-dimethanol terephthalate) (PET) or poly (ethylene-co-cyclohexane 1,4-dimethanol terephthalate glycol) (PETG); glycol modified polycyclohexylenedimethlene terephthalate (PCTG); 1,4-cyclohexanedimethanol (CHDM); polycarbonate (PC) materials, and the like. Materials used in producing polymeric resin panels may also include any number of similar resins or resin alloys that trace their component origins to derivatives of petroleum processing.
Resin panels are popular compared with decorative cast or laminated glass panels, since resin panels are generally more resilient and less costly than glass panels, while having a similar transparent, translucent, or decorative appearance. Decorative resin panels may also provide greater design flexibility as compared with glass panels, at least in terms of color choices, degree of texture, thickness, and overall physical characteristics, such as flexibility and impact resistance. Furthermore, decorative resin panels have wide utility since manufacturers can easily and inexpensively form and fabricate single or multi-layer laminate resin panels that include a large variety of artistic designs, images, shapes, structures, and assemblies. Furthermore, manufacturers can economically produce resin panels as either flat sheets or three-dimensional (i.e., curved or shaped) formations, that can potentially include compound curvatures. As a result, resin panels have a fairly wide functional and aesthetic utility, and provide designers and architects with the ability to readily change the design and function of new and existing structures.
When producing flat resin sheets, manufacturers often produce the sheets in standard sizes, which may vary between large sheets (e.g., 5′×10′) to small tiles (e.g., 6″×6″). Manufacturers can even produce custom-sized resin sheets as ordered by a purchaser. In either case, during the manufacturing process, manufacturers typically form resin sheets that are larger than the standard or customer-defined sizes eventually sold. This can be due to the size of the manufacturing equipment used to create the resin sheets, or out of a desire to trim the excess material from one or more edges of the resin sheets. Edge trimming can create a clean edge on the final product, and can provide squared and uniform panel geometries suitable for commercial distribution.
Unfortunately, this practice creates a sizeable waste stream, including edge trimmings (i.e., resin material trimmed from one or more edges of resin sheets) and other left-over resin portions not sold as a final consumer product. The size of this waste stream can be exasperated when producing custom-sized resin panels, as the portion(s) of a resin sheet used for the final panel product(s) may be significantly smaller than the originally-produced resin sheet. Panel manufacturers have conventionally sent waste trimmings to landfills due, at least in part, to the fact that waste trimmings are difficult to incorporate into traditional recycling streams. This is a particular problem for the environment, as resin materials do not typically break down or degrade for significant time durations. Not only do resin materials degrade at poor rates, but the source of some common resins (i.e., fossil-based hydrocarbons, such as petroleum), is generally thought to be non-replenishing, and continually under pressure of exhaustion and market instability.
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 produce variable interlayer laminate panels including resin portions sourced from other resin panels. Specifically, implementations of the present invention comprise apparatus and methods for laminating a plurality of resin portions, sourced from other resin panels, between two resin sheets using primarily heat and pressure. In at least one implementation, the resin portions can include waste trimmings, enabling a manufacturer to produce a high-fashion, but waste-conscious resin panel that the manufacturer can sell and market as having a high percentage of recycled content.
For example, one implementation of a method of manufacturing a laminate resin panel can involve a manufacturer forming a panel assembly, including the manufacturer positioning a first resin substrate in the panel assembly. The manufacturer can also position a plurality of independent resin portions over the first resin substrate. Each independent resin portion can comprise embedded decorative elements, with at least two different resin portions comprising different types of decorative elements. The manufacturer can then position a second resin substrate over the plurality of independent resin portions. Subsequently, the manufacturer can apply a combination of heat and pressure to the panel assembly until the resin portions fuse together and also fuse to the first resin substrate and to the second resin substrate.
An implementation of a laminate panel can comprise a first resin substrate and an opposing second resin substrate. The laminate panel can also comprise an interlayer positioned between and fused to the first resin substrate and the opposing second resin substrate. The interlayer can comprise a plurality of resin portions, including a first resin portion fused to a second resin portion. The first resin portion can have a first decorative element embedded therein, and the second resin portion can have a second decorative element embedded therein, the second decorative element being different from the first decorative element.
Furthermore, a panel system can include a laminate panel and one or more fasteners attaching the laminate panel to a support structure. The laminate panel can include a first resin substrate and an opposing second resin substrate, with an interlayer positioned between and fused to the first and second resin substrates. The interlayer can comprise a plurality of fused resin portions, including a first resin portion that comprises a first embedded decorative element and a second resin portion that comprises a second embedded decorative element. The second embedded decorative element is of a different material than the first embedded decorative element.
Additional features and advantages of exemplary implementations of the present 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. 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:
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 produce variable interlayer laminate panels that include resin portions sourced from other resin panels. Specifically, implementations of the present invention comprise apparatus and methods for laminating a plurality of resin portions, sourced from other resin panels, between two resin sheets using primarily heat and pressure. In at least one implementation, the resin portions can include waste trimmings, enabling a manufacturer to produce a high-fashion, but waste-conscious resin panel that the manufacturer can sell and market as having a high percentage of recycled content.
In general, and as understood more fully herein, a manufacturer can produce variable interlayer laminate panels having a plurality layers, including a first outer layer (i.e., a first resin substrate) and a second opposing outer layer (i.e., a second resin substrate). Positioned between the outer layers, the variable interlayer laminate panel can include at least one variable interlayer, such as a decorative interlayer, made up of a plurality of independent pieces or portions of resin material. Preferably, one or more of the outer layers comprise a substantially transparent resin material that provides at least a partial view of the variable interlayer. The pieces forming the variable interlayer can also comprise an at least partially transparent resin material, as well as one or more decorative elements (either resin or non-resin). At least one of the pieces or portions making up the interlayer can originate from other resin panels, such as one or more waste trimmings generated while manufacturing one or more other resin panels.
As such, a part, or even all, of the resin material forming the variable interlayer can comprise pre-consumer recycled material. Reuse of waste trimmings, such as edge trimmings and other leftover resin portions, by a manufacturer producing resin panels can yield gains for the manufacturer, for consumers, for the environment, and for others. Gains include, for example, cost savings for manufacturers and consumers brought about through an overall reduction in the amount of source resin material required to produce resin panels, as well a reduction in disposal costs. Gains also include benefits to the environment and to society as a whole brought about by a reduction in waste and a reduction in the use of fossil-based hydrocarbon resources when producing resin panels. The production of resin panels with recycled content can also generate goodwill for the manufacturer and for consumers using the panels, and can expand the market for resin panels to include the growing community of environmentally-conscious consumers.
In addition, producing resin panels having a high percentage of recycled resin content can help manufacturers and consumers alike meet professional certification with environmentally-conscious organizations. Many manufacturers, suppliers, architects, designers, and other businesses favor manufacturing methods and materials that exhibit environmental stewardship and responsibility. For example, LEADERSHIP IN ENERGY AND ENVIRONMENTAL DESIGN (LEED) certification tallies points for environmentally sound building practices, such as the use of recycled industrial waste, in a building project. LEED provides more points for use of higher percentages of recycled content, which can contribute to a “Green Building” certification, a designation that is important as a value-add for many designers, architects, and building owners. Material suppliers that offer building supplies with recycled material content may enjoy a significant market advantage over their competitors as environmental concerns and certifications continue to become an important part of material specification.
As a preliminary matter, as used herein the phrases “resin substrate” and “resin sheet” mean single or multi-layer substrates or sheets formed from 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, resin substrates and sheets 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.
Referring now to the Figures,
As discussed more fully herein after, the resin portions (e.g., one or more of resin portions 102a, 102b, 102c, and 102d) can comprise resin portions sourced from one or more other resin panels. For instance, the resin portions can comprise waste trimmings left over from the manufacture of other resin panels, which can result in a variable interlayer 102 (and consequently a resin panel 100) having a potentially high percentage of recycled content. The resin portions can also comprise non-waste portions of other resin panels. In one or more implementations, the resin portions include at least some resin portions sourced from different resin panels, each having different aesthetic characteristics. The plurality resin portions can thus include a variety of aesthetic qualities (e.g., embedded decorative elements, colors, transparency), enabling a manufacturer to combine resin portions from different resin panels to create a variable interlayer 102 having distinctive aesthetic arrangements.
In one or more embodiments, the air transfer layer(s) 103a and/or 103b comprise spunbound polyester, which includes fibers that create pathways through which air can travel during the fusing process. As a result, pressures (e.g., mechanical and/or vacuum pressure) applied during the fusing process can push and/or pull air out of the laminate panel through these pathways. Furthermore, heat applied during the fusing process melts the fibers, making them substantially undetectable to the human eye. Manufacturers can employ any number of other air transport materials, so long as they enable the transport of air out of the variable interlayer laminate panel assembly 100 and/or do not substantially interfere with the translucent or transparent properties of the layers of the variable interlayer laminate panel assembly 100.
Manufacturers can vary the thickness of each layer in the variable interlayer laminate panel assembly 100 to optimize various characteristics of the finished panel. For example, a manufacturer or consumer may want to maximize the amount of recycled content of the variable interlayer 102 in order to accumulate LEED points for a given project, or to market the resin panel 100 as being environmentally friendly. In this case, the manufacturer may construct the variable interlayer 102 from waste trimmings, and/or increase the thickness of the variable interlayer 102 in relation to the outer layers, thereby increasing the percentage of recycled content in the resin panel 100 on a mass basis. An additional benefit of using waste trimmings for the variable interlayer 102 is an overall decrease in the material cost for the resultant variable interlayer laminate panel, since the manufacturer need not purchase new resin for the variable interlayer 102. The manufacturer can also increase the amount of recycled content of the variable interlayer laminate panel assembly 100 by using resin substrates 101a, 101b that are at least partially comprised of pre-consumer or post-consumer recycled resins.
Decreasing the thickness of the resin substrates 101a, 101b may lead to an increased occurrence of surface blemishes on the finished variable interlayer laminate panel. As a result, the manufacturer can generally only decrease the thickness of the resin substrates 101a, 101b to a certain threshold. This threshold is generally a dynamic threshold, which varies based on a ratio between the thicknesses of the variable interlayer 102 and the thickness of the outer resin substrates 101a, 101b.
In one or more implementations, variable interlayer laminate panels in accordance with the present invention can have about 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or about 100% by weight (or alternatively by volume) of pre-consumer recycled content. For example, a variable interlayer laminate panel having approximately 75% recycled material could include a variable interlayer 102 having a substantially uniform thickness of about ¼ inch (e.g., 0.263 inches) and comprising 100% recycled waste trimmings. The resin variable interlayer laminate panel could also include two resin substrates 101a, 101b forming outer layers, each having a thickness of about 1/10 inch (e.g., 0.090 inches). The resin substrates 101a, 101b can also include some recycled content, such as about 40%. The variable interlayer laminate panel, when manufactured according to these specifications, would have an overall thickness of less than ½ inch. Any air transfer layer(s) 103a and/or 103b would add negligible thickness and mass to the finished resin panel.
Of course, manufacturers can use other thicknesses and/or other levels of recycled content. For example, in one or more implementations the variable interlayer 102 can have a thickness of about ⅜ inch. Additionally, one or more of the resin substrates 101a, 101b or the variable interlayer 102 can use a lower amount of recycled material (or even no recycled material) or a higher amount of recycled material. Accordingly, the above-illustrated example if for illustration only and is non-limiting.
Turning to
After assembling the variable interlayer laminate panel assembly 100, the manufacturer can laminate/fuse the resin components of the variable interlayer laminate panel assembly 100 together through the application of heat and pressure. For instance, as shown, the manufacturer can raise the temperature (T) and the pressure (P) of the variable interlayer laminate panel assembly 100, thereby melting the resin components beyond their glass transition temperature. Doing so fuses adjoining resin portions of the variable interlayer 102 to one another, and also fuses the variable interlayer 102 and the resin substrates 101a, 101b to one another. The particular temperature (T) and pressure (P) employed are dependent on the types of resins used, the thicknesses of the substrates 101a, 101b and the variable interlayer 102, and whether the manufacturer uses adhesives and/or air transport layers 103a, 103b.
In one or more implementations, the manufacturer can apply a temperature of between about 180 degrees Fahrenheit (° F.) and about 400° F., and apply a pressure between approximately 5 pounds per square inch (psi) and approximately 250 psi. Preferably, the pressure is between about 5 psi and about 90 psi. The manufacturer can hold the variable interlayer laminate panel assembly 100 at the appropriate temperature and pressure until the resin components fuse, such as for about 0.1 minutes to about 20 minutes. The manufacturer can apply heat and pressure using any appropriate mechanism, such as with a heated mechanical press or with an autoclave. When heating with a heated mechanical press, the manufacturer can make use of various heating methods, including steam, electric heat, heated oil, etc.
The manufacturer may also employ a vacuum to remove air from the variable interlayer laminate panel assembly 100. For example, the manufacturer can reduce the air pressure prior surrounding the variable interlayer laminate panel assembly 100 prior to pressing with a mechanical press or autoclave. Additionally or alternatively, the manufacturer can make use of a mechanical press that applies pressure to the variable interlayer laminate panel assembly 100 mechanically, while concurrently reducing the air pressure around the panel assembly to aid in removing air from the panel assembly.
Following the application of heat and pressure, the manufacturer can allow the laminated/fused variable interlayer laminate panel 200 to cool below the glass transition temperature of the resin material while holding the panel assembly rigid. For instance, the manufacturer can reduce the temperature of the variable interlayer laminate panel 200 to between about 50° F. about 120° F., and hold the panel assembly at a pressure of between about 1 psi and about 120 psi. Once the variable interlayer laminate panel 200 cools below the glass transition temperature, the manufacturer can remove the fused variable interlayer laminate panel 200 from the pressing mechanism.
As indicated, the manufacturer can source the resin portions (e.g., resin portions 102a, 102b, 102c, and 102d of
In one or more implementations, however, the other resin panels may not embed decorative materials. For example,
As illustrated, resin panels 300a and 300b have already been finished, or trimmed to size.
For instance, the manufacturer may trim each panel edge, as illustrated by the dashed lines, resulting in waste trimmings that may include decorative materials. For example, when the manufacturer trims edge 401d at dashed line 402, the waste trimming 403 contains a portion of a bamboo ring 404. Because there can be limitless configurations of decorative materials within the panel 400, the waste trimming 403 can, in turn, contain a vast array of unique aesthetic qualities. For example, the waste trimming 403 may contain no decorative materials, or may contain entire pieces of decorative material and/or mere portions of decorative material. The manufacturer may choose not to trim every panel edge, or may use differing trimming configurations, such as curves, saw tooth configurations, or any other decorative form.
In addition, the manufacturer may trim each edge more than once. In one or more implementations, trimming an edge may involve a first “rough” trimming process that yields fast yet less precise or less clean cut, and one or more subsequent trimming processes that gradually refine the edge. It is therefore possible for the trimming of a single resin panel to generate a variety of waste trimmings having various widths and geometries. The manufacturer can use any of these waste trimmings as one of the plurality of resin portions (e.g., 102a-102d) that form the variable interlayer 102 of the variable interlayer laminate panel 200.
Manufacturers may also use portions of decorative panels not normally classified as waste to construct the variable interlayer laminate panel 200. For instance, manufacturers may produce or purchase resin panels, such as resin panels 300a, 300b, or 400, for the purpose of generating “non-waste” trimmings for use as the resin portions (e.g., 102a-102d) that form the variable interlayer 102. Along these lines,
Use of resin portions sourced from other resin panels enables manufacturers to “mix-and-match” resin portions from different resin panels having distinct and different designs. Manufacturers can therefore fabricate a variable interlayer laminate panel 200 having a plurality of different types of decorative elements embedded therein, without complicating the processes of embedding those decorative materials in variable interlayer laminate panel 200. Because of the aesthetic appeal of such arrangements, manufacturers may produce panels (e.g., panels 300a, 300b, or 400) for the express purpose of later dividing at least a portion of these panels into smaller pieces for later re-assembly as a variable interlayer 102. Therefore, in addition to enabling manufacturers to reduce waste and produce environmentally-friendly panels, the inventive implementations described herein also enable great flexibility in producing distinctive designs.
It may be possible to use waste or non-waste trimmings in the production of a variable interlayer laminate panel 200 without any additional modification to the edges of the trimmings. It may be desirable; however, to further modify the trimmings for use in the variable interlayer 102.
While
It will be appreciated that the resin portions sourced from other resin panels can comprise single or multi-layer resin portions. For instance, the other resin panels may include multiple layers, such as outer layers, interlayers, decorative resin layers, decorative films, air transport layers, adhesives, etc. As such, resin portions sourced from these panels may also include these layers. In one or more implementations, the other resin panels may even be manufactured according to the implementations described herein.
As shown by
Accordingly,
For example,
While not shown, act 730 can involve further trimming the resin portions to that they fit cleanly with one another and so that they fit within a desired arrangements. As shown in
Although not shown, a manufacturer can also perform an act of positioning one or more air transport layers. In particular, the act may include positioning one or more air transport layers between one or both of the plurality of independent resin portions and the first resin substrate and/or the plurality of independent resin portions and the second resin substrate in the panel assembly, wherein the one or more air transport layers transport air out of the panel assembly during the application of the combination of heat and pressure. For example, as shown in
Also not shown, the manufacturer may position one or more decorative outer layers on one or both of the first resin substrate 101b and/or the second resin substrate 101b. In this way, the manufacturer can add additional color and/or texture to the resin panel 100. In one or more implementations, the decorative outer layers may comprise a film applied to the resin substrate(s).
Furthermore,
In one or more implementations, the method can comprise applying a second combination of heat and pressure to the panel assembly. In particular, after passing through a heat and pressure cycle as described above in relation to act 750, the manufacturer run the panel assembly through a second heat and pressure cycle of with a temperature of between about 180° F. and about 400° F. and a pressure of between about 5 psi and about 250 psi for a time period of between about 0.1 minutes and about 20 minutes. In particular, it may be desirable to run the panel assembly through a second heat and pressure cycle when using resin portions (102a-102d) having different gauges and/or sizes. In such implementations, the second heat and pressure cycle can help reduce surface variations and flaws in the final panel.
In any event, once formed, an end-user can arrange variable interlayer laminate panels produced as described herein into a panel system. For example,
In any event, panel system 800 can add to the functional and/or aesthetic characteristics of a given structure of design space. Thus, one will appreciate that implementations of the present invention provide a manufacturer with a number of ways to prepare a structurally useful, aesthetically desirable variable interlayer laminate panels. These variable interlayer laminate 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, the schematics and methods described herein provide a laminate resin panel that can include resin material derived from other resin panels, enabling use of decorative resin pieces or portions from the other resin panels. The schematics and methods can also enable the recycling of waste trimmings from the manufacture of the other resin panels. Implementations therefore enable manufacturers to produce high-fashion but waste conscious resin panels that contain a high level of recycled content.
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 invention is a 371 U.S. National Stage of PCT Application No. PCT/US2011/054058, filed Sep. 29, 2011 entitled “VARIABLE INTERLAYER LAMINATE PANELS AND METHODS OF FORMING THE SAME” which claims the benefit of and priority to U.S. Provisional Application No. 61/387,209, filed Sep. 28, 2010, entitled “Laminated Sheets Containing Randomized Variable Interlayers,” the entire content of which is incorporated by reference herein.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/US2011/054058 | 9/29/2011 | WO | 00 | 3/7/2013 |
